Double-sided transcription type sheet/film forming roll apparatus and double-sided transcription type sheet/film forming method

ABSTRACT

An apparatus includes a first roll and a second roll on each of which a pattern is formed, a first motor and a second motor to rotate the respective rolls, a shaft direction supporting mechanism to support the second roll along a shaft direction and an axial position adjusting mechanism configured to move the shaft direction supporting mechanism along the shaft direction. The posture of the rotating shaft of the second motor is maintained constant at all times, and the second roll is moved in the shaft direction along the first roll, thereby adjusting the positions of both patterns on the first roll and the second roll along the shaft direction.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based upon and claims the benefit of priority fromprior Japanese Patent Application No. 2017-141032, filed Jul. 20, 2017,the entire contents of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to a sheet/film manufacturing (forming)technique for manufacturing (forming) a sheet or a film, on bothsurfaces of which patterns are transcribed, without causing a gear mark(i.e., horizontal stripes).

2. Description of the Related Art

In a sheet/film manufacturing (forming) technique, for example, a moltenresin is discharged from a T-die in a thin and spread form. Thedischarged molten resin is fed into a part between two rolls rotating inopposition to each other. The gap between the rolls is controlled. Thus,a sheet or a film appropriate for the intended purpose or use iscontinuously manufactured (formed). Here, Patent Literatures 1 (JPH10-249909 A), 2 (JP H08-25458 A), 3 (JP S62-35815 U), and 4 (JP2005-1170 A) in which apparatuses associated with sheet/filmmanufacturing (forming) techniques are disclosed are known.

In the apparatus of Patent Literature 1, each of a reference roll, anddriven rolls arranged on both sides of the reference roll isdrive-controlled by a precision control motor through a shaft couplingand a reducer. Each of the rolls is stably rotated. Thus, the opticalcharacteristics of the sheet can be improved. In other words,retardation of the sheet becomes small.

In the apparatus of Patent Literature 2, a sheet-like substance ispressed between a first roll and a second roll rotating in opposition toeach other and, is thereafter cooled by a third roll. The surfacetemperatures of the first to third rolls, and the speed of receiving thesheet from the third roll are controlled to within the ranges set inadvance. Thus, a polycarbonate sheet in a fine surface condition,without a bend or a curve, and excellent in flatness can be obtained.

In the apparatus of Patent Literature 3, a planetary roller reducerrequiring no ears is employed in place of a gear reducer. A plasticsheet is manufactured (formed) without causing a backlash peculiar to agear mechanism. Thus, a plurality of gear marks (horizontal stripes) areprevented from occurring on the sheet surface in a directionintersecting the feed direction of the sheet.

In the apparatus of Patent Literature 4, a so-called direct-drive drivemechanism is employed as a roll drive system. In such as drivemechanism, the motor (rotor) is directly coupled to the roll (driveshaft part) (i.e., direct coupling) in a state where all the types ofreducers including the gear reducer and the planetary roller reducer areexcluded. Thus, in a state where the rotation central axis of the roll(drive shaft part) is maintained in a fixed posture, in other words, ina state where the rotation central axis of the motor (rotor) ismaintained in a fixed posture, a sheet or a film is manufactured(formed) without causing gear marks (horizontal stripes).

However, in the apparatuses of Patent Literatures 1 and 2, the formingconditions and the operation conditions are limited. That is, theintended purpose or use is limited. For this reason, the apparatuses aredeficient in diversity. The apparatus of Patent Literature 3 needs tosecure a large installation location for the planetary roller reducer.That is, the planetary roller reducer has a complicated structure.Accordingly, the whole apparatus has to be inevitably made larger. Forthis reason, reduction in the size of the whole apparatus has a certainlimit.

Furthermore, regarding the apparatus of Patent Literature 4, theinventers of the present invention have found the fact that there is thefollowing problem in the process of earnestly carrying out research anddevelopment. The apparatus of Patent Literature 4 is specified in such amanner that a roll directly coupled to the motor is rotated.

Incidentally, while the motor is operating, torque ripples occur in themotor. Torque ripples imply a ripple phenomenon caused by the mutualinteraction of magnetic flux components between the stator and the rotorwhen a current is made to flow through the motor to thereby causerelative rotation between the stator and the rotor.

In this case, when an amplitude of a certain frequency component(wavelength component) among frequency components (wavelengthcomponents) constituting the torque ripples (pulsation phenomenon)exceeds, for example, a threshold, gear marks (horizontal stripes) of anamplitude corresponding to the amplitude of the frequency component(wavelength component) occur in some cases.

In the specification of the Patent Literature 4, a molten resindischarged from a T-die is fed into a part between two rolls rotating inopposition to each other. At this time, for example, operationconditions or forming conditions such as adjustment of the gap betweenthe rolls, rotation-control of the motor or the like are set. Thus, asheet or a film is continuously manufactured (formed) without causinggear marks (horizontal stripes).

During such a manufacturing (forming) process, in order to carry out,for example, thickness adjustment of the formed product or disturbancecorrection, the state (for example, posture, and angle) where one rollis pressed against the other roll is changed. At this time, theinfluence of the pressed state of the one roll on the other roll, i.e.,the changed state of the other roll is directly transmitted to themotor. In other words, the bent states of both the rolls are changed,and the changed bent states are directly transmitted to the motor.Thereby, the posture of the rotation central axis of the motor concernedis changed. When the posture of the rotation central axis of the motoris changed, the amplitude of the torque ripples (pulsation phenomenon)described above is changed correspondingly.

The change in amplitude of the torque ripples (pulsation phenomenon)corresponds to a change in amplitude of each of the various frequencycomponents (wavelength components) occurring in the rotating motor.Here, when an amplitude of a certain frequency component (wavelengthcomponent) exceeds, for example, the threshold, in other words,depending on the degree of the magnitude of the pressed state of the oneroll, gear marks (horizontal stripes) corresponding to the amplitude(amplitude of the frequency component (wavelength component)) occur insome cases.

At this time, not only gear marks (horizontal stripes) based on a singlefrequency component (wavelength component), but also gear marks(horizontal stripes) based on a result of duplication of a plurality offrequency components (wavelength components) occur in some cases. Thus,on the surface of the sheet (film), a plurality of gear marks(horizontal stripes) occur in a direction intersecting the feeddirection of the sheet (film).

In FIG. 21, image data obtained by shooting a plurality of gear marks(horizontal stripes) is shown. In the image data, a plurality of gearmarks (horizontal stripes) have occurred on the surface of the sheet(film) in the direction intersecting the feed direction of the sheet(film). In FIG. 21, a plurality of gear marks (horizontal stripes)having predetermined regularity or periodicity are shown as an example.The occurrence timing (period, interval (pitch)) of the plurality ofgear marks (horizontal stripes) is about 30 mm or less.

Such gear marks (horizontal stripes) constitute a primary factor ofdeteriorating the external appearance and optical characteristics of thesheet (film). For this reason, a technique capable of maintaining theposture of the rotation central axis of the motor constant even when thestate where the one roll is pressed against the other roll is changed,in other words, a technique by which the influence of the pressed stateof the one roll on the other roll, i.e., a changed state of the otherroll is prevented from being transmitted to motor is required.

In addition, the gear mark (horizontal stripes) may create a problemalso when manufacturing (forming) the sheet (film) on both surfaces ofwhich patterns are transcribed. For example, when the thickness of thesheet (film) changes subtly with a gear mark (horizontal stripe), it maybecome impossible to maintain the transcription depth of the patterns atconstant or degrade optical homogeneity depending on the amount changed.

Further, in the specification of transcribing patterns to both surfacesof a sheet (film), for example, two rolls with the patterns formed ontheir transcription surfaces, are employed, which are, namely, a rollwhich transcribes patterns on a front surface of a sheet (film) and aroll which transcribes patterns on a rear surface of the sheet (film).

Incidentally, in some cases, the rolls may be shifted with relative toeach other along the shaft direction while the apparatus are beingdriven. In this case, the shift appears as a displacement between thepatterns on these surfaces of the sheet (film). Here, depending on theamount of displacement of the patterns, it may not be possible tomanufacture (form) sheets (films) of a predetermined quality. Underthese circumstances, there is a demand for such a technology ofadjusting the positions of two rolls (patterns) along the shaftdirection with respect to each other before starting the transcriptionof patterns or during transcribing to prevent the occurrence of suchproblems.

An object of the invention is to provide a technique of manufacturing(forming) a sheet (film) of a predetermined quality by preventingdisplacement of the patterns on both surfaces of a sheet (film) whileavoiding the generation of a gear mark (horizontal stripe) beforehand.

BRIEF SUMMARY OF THE INVENTION

According to an embodiment, the apparatus comprises a first roll and asecond roll, on which patterns are formed, a first motor and a secondmotor to rotate the respective rolls and a second power transmissionmechanism (an intermediate shaft member, two shaft couplings), andfurther comprises an shaft direction supporting mechanism which supportsthe second roll along the shaft direction so as to be rotatable, and ashaft-direction position adjusting mechanism which moves theshaft-direction position adjusting mechanism along the shaft direction.Thus, while the posture of the rotating shaft of the second motor ismaintained constant at all times, and by moving the second roll in theshaft direction along the first roll, the positions of the patterns ofboth the first roll and the second roll along the shaft direction areadjusted.

With the present invention, it becomes possible to realize a techniqueof manufacturing (forming) a sheet (film) by inhibiting the occurrenceof gear marks (horizontal stripes) beforehand while preventingdisplacement between patterns on both surface of the sheet.

Additional objects and advantages of the invention will be set forth inthe description which follows, and in part will be obvious from thedescription, or may be learned by practice of the invention. The objectsand advantages of the invention may be realized and obtained by means ofthe instrumentalities and combinations particularly pointed outhereinafter.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

The accompanying drawings, which are incorporated in and constitute apart of the specification, illustrate embodiments of the invention, andtogether with the general description given above and the detaileddescription of the embodiments given below, serve to explain theprinciples of the invention.

FIG. 1 is a perspective view schematically showing the basicconfiguration of a sheet/film manufacturing apparatus according to afirst embodiment.

FIG. 2 is a plan view of the sheet/film manufacturing apparatus of FIG.1.

FIG. 3 is a side view showing the configurations of the first and thirdpower transmission mechanisms of FIG. 2.

FIG. 4 is a plan view of a sheet/film manufacturing apparatus accordingto a second embodiment.

FIG. 5 is a plan view of a sheet/film manufacturing apparatus accordingto another configuration of the second embodiment.

FIG. 6 is a side view showing the configurations of the first and thirdpower transmission mechanisms of FIG. 5.

FIG. 7 is a cross-sectional view of a first and second rolls associatedwith a compression state.

FIG. 8 is a cross-sectional view of the first and second rollsassociated with a press state.

FIG. 9 is a cross-sectional view of the first and second rollsassociated with a touch/contact state.

FIG. 10 is a block diagram showing the configuration of a hydraulicservo type push-pull mechanism.

FIG. 11 is a cross-sectional view showing the internal configuration ofa motor using permanent magnets.

FIG. 12 is a perspective view showing the configuration of a rotatingshaft part which can be fitted into a motor.

FIG. 13 is a perspective view showing the configuration of a rotatingshaft part which can be attached to the motor.

FIG. 14 is a perspective view showing the configuration of a rotatingshaft part formed integral with the motor.

FIG. 15 is a perspective view showing the configuration of a secondpower transmission mechanism.

FIG. 16 is a plan view of a sheet/film manufacturing apparatus accordingto a third embodiment.

FIG. 17 is a perspective view showing the configuration of the first andthird power transmission mechanism of FIG. 16.

FIG. 18 is a plan view of a sheet/film manufacturing apparatus accordingto a fourth embodiment.

FIG. 19 is a view showing a state where the thickness of the moltenresin is varied by making the first roll carry out a reciprocatingmotion with respect to the second roll at the time of a gear mark(horizontal stripes) occurrence test.

FIG. 20 is a view schematically showing the state where the thickness ofthe molten resin of FIG. 19 is varied.

FIG. 21 is an image view of a conventional sample in which gear marks(horizontal stripes) have occurred.

FIG. 22 is an image view of a sample of the present invention in whichgear marks (horizontal stripes) are prevented from occurring.

FIG. 23 is a perspective view schematically showing the basic structureof a sheet/film manufacturing apparatus according to a fifth embodiment.

FIG. 24 is a plan view of the sheet/film manufacturing apparatus of FIG.23.

FIG. 25 is a block diagram showing the structure of a hydraulic servotype positioning mechanism.

FIG. 26 is a partially expanded cross sectional view showing thestructure of a contact point between a first roll and a second roll.

FIG. 27 is a cross sectional view showing the structure of athrust-bearing mechanism supporting along the shaft direction.

DETAILED DESCRIPTION OF THE INVENTION

[Situation Up to Present Invention]

As a result of research and development earnestly carried out by theinventors of the present invention with respect to the sheet/filmmanufacturing (forming) technique in which the motor (rotor) and theroll (drive shaft part) are coupled to each other in a state where allthe reducers are excluded, the present invention has been developed asshown in the following items (1) to (6).

(1) In the technical research concerned, a roll structure in which aroll is directly coupled to a motor is employed. That is, a first motoris directly coupled to a first roll. A second motor is directly coupledto a second roll. The first roll and the second roll are rotated inopposition to each other. Operation conditions and forming conditionsare set in such a manner that no gear marks (horizontal stripes) occur.In such a state, a molten resin is fed into a part between the firstroll and the second roll.

(2) During the manufacture (formation) of a sheet (film), in order tocarry out, for example, thickness adjustment of the formed product ordisturbance correction, the state (for example, posture, and angle)where the first roll is pressed against the second roll is changed.Then, a plurality of stripes similar to gear marks have occurred. Theoccurrence timing (period, interval (pitch)) of such stripes (i.e., gearmarks (horizontal stripes)) is approximately coincident with theoccurrence timing (period, interval (pitch)) of the torque ripples ofthe second motor. In this case, the influence of the torque ripples ofthe first motor on the occurrence of the stripes (gear marks (horizontalstripes)) is comparatively small.

(3) The occurrence timing (period, interval (pitch)) of the stripes(gear marks (horizontal stripes) is strongly influenced by torqueripples caused by a cogging phenomenon. The cogging phenomenon implies apulsation phenomenon caused by variation in the magnetic reluctancebetween the stator (coils) and the rotor (permanent magnets) when thestator (coils) and the rotor (permanent magnets) are relatively rotatedwithout making a current flow through the motor.

(4) The state (for example, posture, and angle) where the first roll ispressed against the second roll is changed. At this time, the influenceof the pressed state of the first roll on the second roll, i.e., thechanged state (for example, the changed state of the posture of therotation central axis of the second roll) of the second roll directlyacts on the rotor of the second motor. In other words, the bent statesof the first and second rolls change, and the changed bent states aredirectly transmitted to the second motor (rotor). Then, the posture ofthe rotation central axis of the rotor changes. Thereby, when the statorand the rotor are relatively rotated, a state where the gap between thestator and the rotor is not maintained constant in the circumferentialdirection, i.e., a state where the gap is irregularly changed in thecircumferential direction is brought about. In such a state, themagnetic reluctance between the stator and the rotor irregularly changesin the circumferential direction. As a result, it becomes impossible torotate the second motor smoothly at a constant speed.

In that case, amplitudes (i.e., magnitude of the torque ripples) ofvarious frequency components (wavelength components) occurring in thesecond motor change. At this time, depending on the degree of themagnitude of the torque ripples of a certain frequency component(wavelength component), gear marks (horizontal stripes) corresponding tothe amplitude of the frequency component (wavelength component) becomeliable to occur.

(5) When the coupled state of the second roll and the second motorbecomes unstable depending on the degree of the state where the firstroll is pressed against the second roll, it cannot necessarily be saidthat the structure in which the second roll and the second motor aredirectly coupled to each other is effective. Thus, a technique formaintaining the posture of the rotation central axis of the second motorconstant, and making the influence of the pressed state of the firstroll on the second roll, i.e., the changed state of the second roll nottransmittable to the second motor is required.

(6) In order to realize such a technique, for example, a rotating shaftpart, and a power transmission mechanism are prepared. The rotatingshaft part is coupled to the second motor (rotor). The powertransmission mechanism is arranged between the roll (drive shaft part)and the second motor (rotor). That is, the roll (drive shaft part) iscoupled to one end side of the power transmission mechanism. The secondmotor (rotor) is coupled to the other end side of the power transmissionmechanism.

According to this configuration, the influence of the state where thefirst roll is pressed against the second roll on the second roll, i.e.,the changed state of the second roll is never transmitted to the secondmotor. In this case, the rotating shaft part coupled to the second motoris maintained in a constant posture at all times. The posture of therotation central axis of the second motor (rotor) is also maintainedconstant at all times. Thereby, it is possible to smoothly rotate thesecond motor (rotor) at a constant speed at all times. As a result, itis possible to maintain the torque ripples of the second motor within arange (level) allowing no occurrence of gear marks (horizontal stripes).

[Sheet/Film Manufacturing Apparatus 1 According to First Embodiment]

As shown in FIG. 1 through FIG. 3, a sheet/film manufacturing apparatus1 includes a sheet/film forming roll unit, discharge unit 2, andtemperature regulating unit 4. The sheet/film forming roll unit isconstituted of a roll unit 3, push-pull unit 5, and drive unit 6.

The discharge unit 2 is configured to be able to discharge a moltenresin 7 a in a thin and spread form. The roll unit 3 is configured to beable to form the discharged molten resin 7 a into a form (for example,shape and thickness) suitable for the use by means of a plurality rolls(first roll 12, second roll 13, and third roll 14) to be describedlater. The temperature regulating unit 4 is configured to be able toregulate the temperatures of the rolls 12, 13, and 14. The push-pullunit 5 is configured to be able to change the state (for example,posture, and angle) where the first and third rolls 12 and 14 arepressed against the second roll 13. The drive unit 6 is configured to beable to control the rotating state of each of the rolls 12, 13, and 14.Hereinafter, specific descriptions will be given.

[Discharge Unit 2]

As shown in FIG. 1, the discharge unit 2 includes an extruding unit 8,and T-die 9. The extruding unit 8 and the T-die 9 are coupled to eachother through a connecting pipe 10. The extruding unit 8 is providedwith a cylinder (not shown), and hopper 11. It should be noted that theextruding unit 8, T-die 9, and connecting pipe 10 are heated to atemperature set in advance, and are kept at the set temperature. The settemperature is a temperature higher than the set temperature of therolls 12, 13, and 14 to be described later.

In the cylinder, one or a plurality of screws (not shown) are rotatablyinserted. According to a specification in which one screw is inserted inthe cylinder, a single-axis extruding unit is configured. According to aspecification in which a plurality of (for example, two) screws areinserted in the cylinder, a biaxial extruding unit is configured.

The hopper 11 is configured to be able to put a resin material into thecylinder. For example, a pellet type resin material is put into thehopper 11. The put resin material is melted by the rotating screw and iskneaded in the cylinder. The molten/kneaded resin material istranscribed to the tip end of the cylinder in a molten state.

The molten resin transcribed to the tip end of the cylinder is fed intothe T-die 9 from the connecting pipe 10. The T-die 9 is configured to beable to discharge the transcribed molten resin in a spreading manner.The molten resin 7 a discharged from the T-die 9 is fed to the roll unit3. As an example of a method of feeding the molten resin 7 a, aspecification according to which the molten resin 7 a is discharged inthe direction of gravity (vertical) from the T-die 9 is shown in thedrawing.

[Roll Unit 3]

As shown in FIG. 1, FIG. 2, and FIG. 7 through FIG. 9, the roll unit 3includes a first roll 12 (pushing roll), second roll 13 (referenceroll), and third roll 14 (separating roll). Each of the first to thirdrolls 12 to 14 is configured to be able to be individuallytemperature-regulated by the temperature regulating unit 4 to bedescribed later. Here, the shaft directions of the first to third rolls12, 13, and 14 are defined as respective directions along first to thirdrotation central axes 12 r, 13 r, and 14 r, which will be describedlater.

The first roll 12 has a first rotation central axis 12 r. On both sidesof the first roll 12, shaft parts rotatable with the first roll 12(first drive shaft part 12 a and second drive shaft part 12 b) arerespectively provided. The first and second drive shaft parts 12 a and12 b are configured to be concentric with the first rotation centralaxis 12 r. The first drive shaft part 12 a is rotatably supported on afirst bearing mechanism 15. The second drive shaft part 12 b isrotatably supported on a second bearing mechanism 16. Thus, the firstroll 12 is supported rotatable around the first rotation central axis 12r while the shaft parts 12 a and 12 b thereof being supported by thebearing mechanisms 15 and 16.

Furthermore, the first roll 12 has a cylindrical first transcriptionsurface 12 s. The first transcription surface 12 s is a mirror-finishedsurface. The first roll 12 (first transcription surface 12 s) isconfigured in such a manner that first roll 12 can be pressed against asecond roll 13 (second transcription surface 13 s) or can be separatedfrom the second roll 13 (second transcription surface 13 s) by thepush-pull unit 5.

The second roll 13 has a second rotation central axis 13 r. On bothsides of the second roll 13, shaft parts rotatable with the second roll13 (for example, a third drive shaft part 13 a and a fourth drive shaftpart 13 b) are respectively provided. The third and fourth drive shaftparts 13 a and 13 b are configured to be concentric with the secondrotation central axis 13 r. The third drive shaft part 13 a is rotatablysupported on a third bearing mechanism 17. The fourth drive shaft part13 b is rotatably supported on a fourth bearing mechanism 18. Thus, thesecond roll 13 is supported rotatable around the second rotation centralaxis 13 r while the shaft parts 13 a and 13 b thereof being supported bythe bearing mechanisms 17 and 18.

Here, the third and fourth bearing mechanisms 17 and 18 are fixed to abase 30 through fixing parts 29 to be described later. Thereby, thesecond roll 13 having the third and fourth drive shaft parts 13 a and 13b rotatably supported respectively on the third and fourth bearingmechanisms 17 and 18 is maintained in a state where the second roll 13is fixed to a given position set in advance at all times.

Furthermore, the second roll 13 has a cylindrical second transcriptionsurface 13 s. The second transcription surface 13 s is a mirror-finishedsurface. The second transcription surface 13 s is configured to be ableto guide the molten resin 7 a discharged from the T-die in the gravity(vertical) direction in the sheet (film) feed direction Fd set inadvance.

The third roll 14 has a third rotation central axis 14 r. On both sidesof the third roll 14, shaft parts rotatable with the third roll 14 (afifth drive shaft part 14 a and a sixth drive shaft part 14 b) arerespectively provided. The fifth and sixth drive shaft parts 14 a and 14b are configured to be concentric with the third rotation central axis14 r. The fifth drive shaft part 14 a is rotatably supported on a fifthbearing mechanism 19. The sixth drive shaft part 14 b is rotatablysupported on a sixth bearing mechanism 20. Thus, the third roll 14 issupported rotatable around the third rotation central axis 14 r whilethe shaft parts 14 a and 14 b thereof being supported by the bearingmechanisms 19 and 20.

Furthermore, the third roll 14 has a cylindrical feed surface 14 s. Thefeed surface 14 s may not necessarily be a mirror-finished surface. Forexample, as will be described in an modified example of the fifthembodiment, a preset pattern may be formed on the feed surface 14 s. Thefeed surface 14 s is configured to be able to guide the molten resin 7 bto be described later in the feed direction Fd.

In this case, the first to third rolls 12, 13 and 14 are controlled tobe in the same rotating state with each other (for example, therotational speed and the number of revolutions). For example, withreference to the rotating state of the second roll 13, the rotatingstates of the first and third rolls 12 and 14 are controlled. Thus, thefirst and third rolls 12 and 14 can be rotated in synchronism with thesecond roll 13.

As one example of the layout of the first to third rolls 12, 13, and 14,a specification in which the first to third rolls 12, 13, and 14 aretransversely arranged is shown in the drawings. In the transversearrangement, the first to third rolls 12, 13, and 14 (i.e., first tothird rotation central axes 12 r, 13 r, and 14 r) are arranged in thehorizontal direction in parallel with each other and at the identicalheight.

Furthermore, the first to third rolls 12, 13, and 14 may be configuredto have diameters identical to each other or may be configured to havediameters different from each other. When the first to third rolls 12,13, and 14 having diameters different from each other are configured, itis desirable that the diameter of the first roll 12 be set smaller thanthe diameter of the second roll 13. Thereby, it is possible to improveor maintain constant the responsibility or the followability of thefirst roll 12.

Here, the responsibility of the first roll 12 implies a speed ofresponse of, for example, a case where the first roll 12 is to bepressed against the second roll 13. The followability of the first roll12 implies a rotational follow-up speed of the first roll 12, forexample, in a state where the first roll 12 is pressed against thesecond roll 13.

In such a configuration, the molten resin 7 a discharged from thedischarge unit 2 (T-die 9) in the gravity (vertical) direction in a thinand spread form passes through a part (contact point G1 (see FIG. 1))between the first roll 12 and the second roll 13. The molten resin 7 awhich has passed through the contact point G1 is cooled while the resin7 a is pushed out along the second transcription surface 13 s of thesecond roll 13, and becomes a molten resin 7 b only the surface of whichhas become solidified. The molten resin 7 b passes through a part(contact point G2 (see FIG. 1)) between the second roll 12 and the thirdroll 13, and thereafter becomes a sheet (film) 7 c in a solidified statethe whole of which has flexibility. Thus, the sheet (film) 7 c is sentin the direction Fd of arrow. At this time, the sheet (film) 7 c has aform (for example, shape, and thickness) corresponding to the use.

Furthermore, the total lengths of the first to third rolls 12, 13, and14 are set to lengths identical to each other. The total lengths of therolls 12, 13, and 14 are defined as lengths in a direction (longitudinaldirection) parallel to the first to third rotation central axes 12 r, 13r, and 14 r. In other words, the total lengths of the rolls 12, 13, and14 are defined as distances between both ends of the rolls 12, 13, and14. In this case, in the state where the first to third rolls 12, 13,and 14 are transversely arranged, the both ends of the rolls 12, 13, and14 are linearly lined up along a direction perpendicular to the rotationcentral axes 12 r, 13 r, and 14 r.

Here, in the first to sixth bearing mechanisms 15, 16, 17, 18, 19, and20 on which the first to sixth drive shaft parts 12 a, 12 b, 13 a, 13 b,14 a, and 14 b of the first to third rolls 12, 13, and 14 are rotatablysupported, the first bearing mechanism 15, the third bearing mechanism17, and the fifth bearing mechanism 19 are linearly lined up in thedirection perpendicular to the first to third rotation central axes 12r, 13 r, and 14 r. Likewise, the second bearing mechanism, the fourthbearing mechanism, and the sixth bearing mechanism are linearly lined upin the direction perpendicular to the first to third rotation centralaxes 12 r, 13 r, and 14 r. In short, the positions at which the rolls12, 13, and 14 are rotatably supported are set at positions identical toeach other along the direction perpendicular to the first to thirdrotation central axes 12 r, 13 r, and 14 r.

It should be noted that as the layout of the first to third rolls 12,13, and 14, longitudinal arrangement or oblique arrangement may beemployed in place of the above-mentioned transverse arrangement althoughnot particularly shown. In the longitudinal arrangement, the first tothird rolls 12, 13, and 14 (i.e., first to third rotation central axes12 r, 13 r, and 14 r) are arranged in parallel with each other in thegravity (vertical) direction. Further, in the oblique arrangement, thesecond roll 13 (second rotation central axis 13 r) is arranged at thecenter, and the first roll 12 (first rotation central axis 12 r) and thethird roll 14 (third rotation central axis 14 r) are arranged on bothsides of the second roll 13 in an inclined state.

Furthermore, the first to third rolls 12, 13, and 14 may be arranged insuch a manner that the third rotation central axis 14 r is notpositioned in the same plane as the first and second rotation centralaxes 12 r and 13 r. Further, the first to third rolls 12, 13, and 14 maybe arranged so that the first and the third rolls 12 and 14 can be movedalong the outer circumference of the second roll 13.

Furthermore, in order to compensate for deficiency in cooling of themolten resin, a fourth roll (not shown) may be provided on thedownstream side of the third roll 14. Further, regarding the third roll14, although the roll 14 is made a constituent article of the roll unit3 of this embodiment, the third roll 14 may be made a constituentarticle of another unit (not shown) according to the intended purpose orthe usage environment.

It should be noted that in FIG. 7 through FIG. 9, the internal structureof each of the rolls 12, 13, and 14 corresponding to the state ofcontact (for example, contact pressure) between the first roll 12 (firsttranscription surface 12 s) and the second roll 13 (second transcriptionsurface 13 s) is shown. Such a contact state (contact pressure) is setin accordance with, for example, the type of the resin, thickness of thesheet (film), use, and the like. In setting the contact state (contactpressure), the state where the first roll 12 is pressed against thesecond roll 13 is adjusted by, for example, the push-pull unit 5 to bedescribed later.

In FIG. 7, the internal structures of the first and second rolls 12 and13 associated with the compression state are shown. The first roll 12 isconfigured in such a manner that a first outer cylinder 22 is arrangedon the outside of a first inner cylinder 21. The second roll 13 isconfigured in such a manner that a second outer cylinder 24 is arrangedon the outside of a second inner cylinder 23. The thickness t1 of eachof the first outer cylinder 22 and the second outer cylinder 24 is setwithin a range of 30 mm≤t1≤60 mm. The contact pressure (linear pressure)in the compression state is set within a range of 30 kgf/cm to 100kgf/cm.

In FIG. 8, the internal structures of the first and second rolls 12 and13 associated with the press state are shown. The first roll 12 isconfigured in such a manner that the first outer cylinder 22 is arrangedon the outside of the first inner cylinder 21. The second roll 13 isconfigured in such a manner that the second outer cylinder 24 isarranged on the outside of the second inner cylinder 23. The thicknesst2 of each of the first outer cylinder 22 and the second outer cylinder24 is set within a range of 10 mm≤t2≤50 mm. The contact pressure (linearpressure) in the press state is set within a range of 20 kgf/cm to 60kgf/cm.

In FIG. 9, the internal structures of the first and second rolls 12 and13 associated with the touch/contact state are shown. The first roll 12is configured in such a manner that the first outer cylinder 22 isarranged on the outside of the first inner cylinder 21. The second roll13 is configured in such a manner that the second outer cylinder 24 isarranged on the outside of the second inner cylinder 23.

Here, when the first outer cylinder 22 has elasticity, the thickness t3of the first outer cylinder 22 is set within a range of 1 mm≤t3≤10 mm,and the thickness t4 of the second outer cylinder 24 is set within arange of 10 mm≥t4≤60 mm. The contact pressure (linear pressure) in thetouch/contact state is set within the range of 5 kgf/cm to 50 kgf/cm.

Further, when the first cylinder 22 is thin-walled, the thickness t3 ofthe first outer cylinder 22 is set within a range of 0.1 mm≤t3≤1 mm, andthe thickness t4 of the second outer cylinder 24 is set within a rangeof 10 mm≤t4≤60 mm. The contact pressure (linear pressure) in thetouch/contact state is set within a range of 1 kgf/cm to 10 kgf/cm.

[Temperature Regulating Unit 4]

As shown in FIG. 2, and FIG. 7 through FIG. 9, the temperatureregulating unit 4 is configured to be able to individually regulate thetemperature of each of the first to third rolls 12, 13, and 14 to atemperature set in advance, and maintain the temperature thereof at theset temperature. As the set temperature of the first to third rolls 12,13, and 14, for example, a temperature at which the molten resin is notfurther melted, and the molten resin can maintain softness while beingsolidified is assumed.

The temperature regulating unit 4 includes first piping 4 a, secondpiping 4 b, and third piping 4 c. The first to third piping members 4 a,4 b, and 4 c are configured in such a manner that a temperatureregulating medium is supplied to them from a supply source (not shown).As an example of the temperature regulating medium, liquid (for example,water and oil) and a coolant can be assumed.

The first piping 4 a is configured, for example, from the second driveshaft part 12 b to the inside of the first roll 12. Inside the firstroll 12, the first piping 4 a is continuous with a first annular area 12p. The first annular area 12 p is configured to be continuous betweenthe first inner cylinder 21 and the first outer cylinder 22 in thecircumferential direction. In such a configuration, the temperatureregulating medium supplied to the first piping 4 a flows from the insideof the first roll 12 through the first annular area 12 p, and isthereafter collected again through the first piping 4 a. Thereby, thetemperature of the first roll 12 (first transcription surface 12 s) isadjusted to the temperature set in advance, and is kept at the settemperature.

The second piping 4 b is configured, for example, from the fourth driveshaft part 13 b to the inside of the second roll 13. Inside the secondroll 13, the second piping 4 b is continuous with a second annular area13 p. The second annular area 13 p is configured to be continuousbetween the second inner cylinder 23 and the second outer cylinder 24 inthe circumferential direction. In such a configuration, the temperatureregulating medium supplied to the second piping 4 b flows from theinside of the second roll 13 through the second annular area 13 p, andis thereafter collected again through the second piping 4 b. Thereby,the temperature of the second roll 13 (second transcription surface 13s) is adjusted to the temperature set in advance, and is kept at the settemperature.

The third piping 4 c is configured, for example, from the sixth driveshaft part 14 b to the inside of the third roll 14. Inside the thirdroll 14, the third piping 4 c is continuous with a third annular area(not shown). The third annular area is configured to be continuousbetween the third inner cylinder and the third outer cylinder which arenot shown in the circumferential direction. In such a configuration, thetemperature regulating medium supplied to the third piping 4 c flowsfrom the inside of the third roll 14 through the third annular area, andis thereafter collected again through the third piping 4 c. Thereby, thetemperature of the third roll 14 (feed surface 14 s) is adjusted to thetemperature set in advance, and is kept at the set temperature.

[Push-Pull Unit 5]

As shown in FIG. 2, FIG. 3, and FIG. 10, the push-pull unit 5 includesfirst to fourth push-pull mechanisms 5 a, 5 b, 5 c, and 5 d, supportingplates 25 and 34, and linear guides 26 to 28, and 35 to 37.

[First and Second Push-Pull Mechanisms 5 a and 5 b]

The first push-pull mechanism 5 a and the second push-pull mechanism 5 bare arranged respectively, for example, on both sides of the first roll12.

The first push-pull mechanism 5 a is configured to be able to exertpressing force and traction force on the first bearing mechanism 15. Thefirst bearing mechanism 15 is supported on the supporting plate 25. Onthe supporting plate 25, a first drive mechanism 53 (drive unit 6) to bedescribed later is mounted. The supporting plate 25 is configured to beable to move along, for example, two linear guides 26 and 27. The twolinear guides 26 and 27 are arranged in parallel with each other and inopposition to each other. The linear guides 26 and 27 are configured ina direction perpendicular to the second rotation central axis 13 r (seeFIG. 1) of the second roll 13.

The second push-pull mechanism 5 b is configured to be able to exertpressing force and traction force on the second bearing mechanism 16.The second bearing mechanism 16 is configured to be able to move along,for example, one linear guide 28. The linear guide 28 is configured in adirection perpendicular to the second rotation central axis 13 r of thesecond roll 13.

In this case, the three linear guides 26, 27, and 28 described above arearranged in parallel with each other and in opposition to each other.These three linear guides 26, 27, and 28 are respectively fixed to, forexample, three fixing parts 29 on a one-to-one basis. Each of the fixingparts 29 is provided on the base 30. The base 30 is configured in such amanner that the base 30 can be attached to a place 32 set in advance bymeans of mounting mechanisms 31 (see FIG. 3). It should be noticed thatas the place 32 set in advance, a place at which the first to thirdrolls 12, 13, and 14 can be laid out in the transverse, longitudinal oroblique arrangement is assumed.

In such a configuration, pressing force or traction force is exerted onthe first bearing mechanism 15. The acting force at that time istransmitted from the first bearing mechanism 15 to the supporting plate25. By the acting force, the supporting plate 25 moves along the linearguides 26 and 27. Following the movement of the supporting plate 25, thefirst bearing mechanism 15 moves together with the first drive mechanism53 (drive unit 6). On the other hand, pressing force or traction forceis exerted on the second bearing mechanism 16. By the acting force atthat time, the second bearing mechanism 16 moves along the linear guide28.

It should be noted that it is desirable that the part (i.e., pressureapplication part 33) at which the pressing force or the traction forceis exerted on the first or second bearing mechanism 15 or 16 by thefirst or second push-pull mechanisms 5 a or 5 b be set at, for example,a position intersecting or perpendicularly intersecting the firstrotation central axis 12 r of the first roll 12, and opposed to aposition immediately above the linear guide 26.

For example, in the case of the specification (see FIG. 2) in which thefirst to third rolls 12, 13, and 14 are arranged in the horizontaldirection in parallel with each other and at the same height (i.e., intransverse arrangement), it is sufficient if the pressing force or thetraction force is exerted on the first and second bearing mechanisms 15and 16 in the horizontal direction and in the direction perpendicular tothe first rotation central axis 12 r. It should be noted that in FIG. 3,the pressure application part 33 of the first bearing mechanism 15 isshown.

As described above, on the first bearing mechanism 15, the first driveshaft part 12 a of the first roll 12 is supported. On the second bearingmechanism 16, the second drive shaft part 12 b of the first roll 12 issupported. Accordingly, when the first and second bearing mechanisms 15and 16 are moved, following the movement, the first and second driveshaft parts 12 a and 12 b move. At this time, together with the firstand second drive shaft parts 12 a and 12 b, the first roll 12 moves.Thus, it is possible to move the first roll 12 toward or away from thesecond roll 13.

At this time, the timing with which the pressing force or the tractionforce is exerted on the first and second bearing mechanisms 15 and 16 iscontrolled. For example, pressing force is exerted on the first bearingmechanism 15, and traction force is exerted on the second bearingmechanism 16. Traction force is exerted on the first bearing mechanism15, and pressing force is exerted on the second bearing mechanism 16.Pressing force is exerted on the first bearing mechanism 15 and thesecond bearing mechanism 16 or traction force is exerted on the firstbearing mechanism 15 and the second bearing mechanism 16. Thereby, it ispossible to adjust the state (for example, posture and angle) where thefirst roll 12 is pressed against the second roll 13 with a high degreeof accuracy and a high degree of resolution.

[Third and Fourth Push-Pull Mechanisms 5 c and 5 d]

The third push-pull mechanism 5 c and the fourth push-pull mechanism 5 dare arranged respectively, for example, on both sides of the third roll14.

The third push-pull mechanism 5 c is configured to be able to exertpressing force and traction force on the fifth bearing mechanism 19. Thefifth bearing mechanism 19 is supported on the supporting plate 34. Onthe supporting plate 34, a third drive mechanism 55 (drive unit 6) to bedescribed later is mounted. The supporting plate 34 is configured to beable to move along, for example, two linear guides 35 and 36. The twolinear guides 35 and 36 are arranged in parallel with each other and inopposition to each other. The linear guides 35 and 36 are configured ina direction perpendicular to the second rotation central axis 13 r (seeFIG. 1) of the second roll 13.

The fourth push-pull mechanism 5 d is configured to be able to exertpressing force and traction force on the sixth bearing mechanism 20. Thesixth bearing mechanism 20 is configured to be able to move along, forexample, one linear guide 37. The linear guide 37 is configured in adirection perpendicular to the second rotation central axis 13 r of thesecond roll 13.

In this case, the three linear guides 35, 36, and 37 described above arearranged in parallel with each other and in opposition to each other.These three linear guides 35, 36, and 37 are respectively fixed to thethree fixing parts 29 described above on a one-to-one basis.

In such a configuration, pressing force or traction force is exerted onthe fifth bearing mechanism 19. The acting force at that time istransmitted from the fifth bearing mechanism 19 to the supporting plate34. By the acting force, the supporting plate 34 moves along the linearguides 35 and 36. Following the movement of the supporting plate 34, thefifth bearing mechanism 19 moves together with the third drive mechanism55 (drive unit 6). On the other hand, pressing force or traction forceis exerted on the sixth bearing mechanism 20. By the acting force atthat time, the sixth bearing mechanism 20 moves along the linear guide37.

It should be noted that it is desirable that the part (i.e., pressureapplication part) at which the pressing force or the traction force isexerted on the fifth or sixth bearing mechanism 19 or 20 by the third orfourth push-pull mechanism 5 c or 5 d be set at, although notparticularly shown, for example, a position intersecting orperpendicularly intersecting the third rotation central axis 14 r of thethird roll 14, and opposed to a position immediately above the linearguide 35.

For example, in the case of the specification (see FIG. 2) in which thefirst to third rolls 12, 13, and 14 are arranged in the horizontaldirection in parallel with each other and at the same height (i.e., intransverse arrangement), it is sufficient if the pressing force or thetraction force is exerted on the fifth and sixth bearing mechanisms 19and 20 in the horizontal direction and in the direction perpendicular tothe third rotation central axis 14 r.

As described above, on the fifth bearing mechanism 19, the fifth driveshaft part 14 a of the third roll 14 is supported. On the sixth bearingmechanism 20, the sixth drive shaft part 14 b of the third roll 14 issupported. Accordingly, when the fifth and sixth bearing mechanisms 19and 20 are moved, following the movement, the fifth and sixth driveshaft parts 14 a and 14 b move. At this time, together with the fifthand sixth drive shaft parts 14 a and 14 b, the third roll 14 moves.Thus, it is possible to move the third roll 14 toward or away from thesecond roll 13.

At this time, the timing with which the pressing force or the tractionforce is exerted on the fifth and sixth bearing mechanisms 19 and 20 iscontrolled. For example, pressing force is exerted on the fifth bearingmechanism 19, and traction force is exerted on the sixth bearingmechanism 20. Traction force is exerted on the fifth bearing mechanism19, and pressing force is exerted on the sixth bearing mechanism 20.Pressing force is exerted on the fifth bearing mechanism 19 and thesixth bearing mechanism 20 or traction force is exerted on the fifthbearing mechanism 19 and the sixth bearing mechanism 20. Thereby, it ispossible to adjust the state (for example, posture and angle) where thethird roll 14 is pressed against the second roll 13 with a high degreeof accuracy and a high degree of resolution.

[Apparatus Configuration of First to Fourth Push-Pull Mechanisms 5 a, 5b, 5 c, and 5 d]

Apparatus configurations identical to each other can be applied theaforementioned first to fourth push-pull mechanisms 5 a, 5 b, 5 c, and 5d. In FIG. 10, as one example, an apparatus configuration of the secondpush-pull mechanism 5 b is shown. The push-pull mechanism 5 b includes ahydraulic servo type actuator 38, and control unit 39. The actuator 38is configured to be able to exert pressing force or traction force onthe second bearing mechanism 16. The control unit 39 is configured to beable to control the actuator 38. Hereinafter, specific descriptions willbe given.

As shown in FIG. 10, the actuator 38 includes a cylinder main body 40,coupling cylinder 41, supporting frame 42, piston 43, and piston rod 44.Inside the cylinder main body 40, a cylinder 45 is configured. To thecylinder main body 40, the coupling cylinder 41 is coupled. The couplingcylinder 41 is supported on the supporting frame 42. That is, thecylinder main body 40 is supported on the supporting frame 42 throughthe coupling cylinder 41.

In the cylinder 45 of the cylinder main body 40, the piston 43 isaccommodated. The piston 43 is configured to be able to move along thecylinder 45 in a reciprocating manner. Inside the cylinder 45, a forwardchamber 45 a and backward chamber 45 b are configured on both sides ofthe piston 43.

The piston rod 44 is configured to extend from the backward chamber 45 balong the cylinder main body 40 and the coupling cylinder 41 in apenetrating manner. A base end of the piston rod 44 is connected to thepiston 43, and a tip end thereof is connected to the aforementionedpressure application part 33 (see FIG. 3).

Here, the forward chamber 45 a is pressurized by the control unit 39and, at the same time, the backward chamber 45 b is decompressed. Atthis time, the piston 43 moves forward. Pressing force is exerted on thepressure application part 33 at the tip end of the piston rod 44. Thepressing force is exerted on the second bearing mechanism 16. Thereby,it is possible to move the second bearing mechanism 16 forward along thelinear guide 28.

Conversely, the forward chamber 45 a is decompressed by the control unit39 and, at the same time, the backward chamber 45 b is pressurized. Atthis time, the piston 43 moves backward. Traction force is exerted onthe pressure application part 33 at the tip end of the piston rod 44.The traction force is exerted on the second bearing mechanism 16.Thereby, it is possible to move the second bearing mechanism 16 backwardalong the linear guide 28.

Furthermore, the control unit 39 includes a controller 46, servo motor47, bidirectional pump 48, first measuring instrument 49, secondmeasuring instrument 50, load cell 51, and pressure sensor 52. Here, asan example, a control unit 39 configured to operate the actuator 38 byhydraulic pressure is assumed.

The controller 46 is configured to be able to control the servo motor 47on the basis of output signals (measurement results) to be describedlater. The servo motor 47 is configured to be able to selectivelycontrol the pressure to be exerted on the forward chamber 45 a or thebackward chamber 45 b by driving the bidirectional pump 48.

In the hydraulic servo system, when the forward chamber 45 a is to bepressurized, oil is supplied from the bidirectional pump 48 to theforward chamber 45 a, whereby the hydraulic pressure in the forwardchamber 45 a is raised. Thus, it is possible to exert pressing force onthe second bearing mechanism 16 as described above. Conversely, when thebackward chamber 45 b is to be pressurized, oil is supplied from thebidirectional pump 48 to the backward chamber 45 b, whereby thehydraulic pressure in the backward chamber 45 b is raised. Thus, it ispossible to exert traction force on the second bearing mechanism 16 asdescribed above.

When pressing force or traction force is exerted on the second bearingmechanism 16, the controller 46 controls the bidirectional pump 48 bymeans of the servo motor 47 on the basis of output signals (measurementresults) from the first measuring instrument 49, second measuringinstrument 50, load cell 51, and pressure sensor 52. For example, thecontroller 46 controls the timing for supplying oil to the forwardchamber 45 a or the backward chamber 45 b, an increment in hydraulicpressure, and the like.

Here, the first measuring instrument 49 is configured to be able tomeasure the position of the piston 43 in the cylinder main body 40(cylinder 45), and output the measurement result. The second measuringinstrument 50 is configured to be able to measure the position of thesecond bearing mechanism 16, and output the measurement result. The loadcell 51 is configured to be able to measure the load exerted on thecoupling cylinder 41, and output the measurement result. The pressuresensor 52 is configured to be able to measure the hydraulic pressure inthe forward chamber 45 a or the backward chamber 45 b, and output themeasurement result.

Thereby, it is possible to exert pressing force or traction force on thesecond bearing mechanism 16 with high accuracy. As a result, it ispossible to vary the state (for example, posture and angle) where thefirst roll 12 is pressed against the second roll 13 with a high degreeof accuracy.

It should be noticed that as the first to fourth push-pull mechanisms 5a, 5 b, 5 c, and 5 d, in place of the aforementioned hydraulic servosystem, although not particularly shown, a system in which the state(for example, posture and angle) where the first or the third roll 12 or14 is pressed against the second roll 13 is changed by moving a screw ora wedge forward or backward may be employed. Further, the supportingplates 25 and 34 are not necessarily indispensable configurations. It issufficient if the structure enables the first and third drive mechanisms53 and 55 (drive unit 6) to be described later to follow the movement ofthe first and fifth bearing mechanisms 15 and 19.

[Drive Unit 6]

As shown in FIG. 1 through FIG. 3, and FIG. 11 through FIG. 14, thedrive unit 6 includes a first drive mechanism 53, second drive mechanism54, and third drive mechanism 55. It should be noticed that the driveunit 6 includes a controller (not shown) configured to control first tothird motors 56, 57, and 58 to be described later. Thereby, it ispossible to collectively or individually control the rotating states(for example, numbers of revolutions, and rotational speeds) of thefirst to third rolls 12, 13, and 14. Hereinafter, specific descriptionswill be given.

[First to Third Motors 56, 57, and 58]

As the first to third motors 56, 57, and 58, multipolar motors using aplurality of permanent magnets are applied. In this case, any types ofmotors including an inner rotor type motor, and outer rotor type motorare applicable. In the inner rotor type motor, a rotor is rotatablyarranged inside a stator. In the outer rotor type motor, a rotor isrotatably arranged outside a stator. Either type of motor can beconfigured by, for example, arranging a plurality of coils on thestator, and arranging a plurality of permanent magnets on the rotor.

In FIG. 11, as an example of the first to third motors 56, 57, and 58,an inner rotor type multipolar motor in which the number of poles iseight, and the number of slots is fifteen is shown. The multipolar motoris configured in such a manner that a rotor 59 (rotating part) canrotate inside a stator 60. On the outer circumference of the rotor 59(rotating part), a plurality of permanent magnets 61 are arranged in thecircumferential direction. Along the outer circumference of the rotor 59(rotating part), S poles and N poles are alternately arranged. On theinner circumference of the stator 60, a plurality of coils 62 arearranged in the inner circumferential direction. In such aconfiguration, the multipolar motor is controlled by the controller.Thus, it is possible to rotate the rotor 59 (rotating part) inside thestator 60.

Here, it is desirable that the second motor 57 directly contributing tothe rotation of the second roll 13 should have a specification whichenables generation of high torque at a low rotational speed. In thiscase, it is desirable, regarding the second motor 57, that the number ofpoles be set to 8 or more, and the number of slots be set to 15 or more.More desirably, regarding the second motor 57, the number of poles isset to 20 or more, and the number of slots is set to 24 or more.Thereby, on the basis of a particular power-supply specification, as thenumber of poles becomes larger, the second motor 57 rotates at a lowerrotational speed, and generates higher torque.

It should be noted that regarding the first motor 56 and the third motor58, a first specification which enables generation of low torque at ahigh rotational speed may be applied, or a second specification whichenables generation of high torque at a low rotational speed as in thecase of the second motor 57 may also be applied. It should be noted thatregarding the first specification, it is necessary to separately providea speed reducer.

In the sheet/film manufacturing apparatus 1 of this embodiment, thepractical rotational speed of the second roll 13 is within the range of0 to 100 rpm. In such a low rotational speed range, the molten resin 7 a(see FIG. 1) is passed through a part (contact point) between the firstroll 12 and the second roll 13, and is sent in the direction Fd ofarrow. For this reason, it is necessary to impart rotational torquesufficient for such feeding to the second roll 13. It is desirable thatthe number of poles of the permanent magnets 61 be set to 20 or more asthe structural requirement for the second motor 57 for satisfying theabove condition.

In this case, it is desirable that the number of slots be set to 24 ormore. It should be noted that as the method of calculating the number ofslots, in, for example, WO2011/114574 “permanent magnet motor”(applicant: Mitsubishi Electric Corporation), the following relationalexpression is shown.Z/{3 (phase)×2P}=2/5 (or 2/7)

-   -   Z: number of slots    -   2P: number of poles (P: natural number)

The number (20) of poles is substituted into the above relationalexpression. Then, the number of slot is calculated as 24. Thereby, it ispossible to generate optimum rotational torque within the range of thepractical rotational speed (0 to 100 rpm) of the second roll 13.

[Arrangement Specification of First to Third Rotating Shaft Parts 64,65, and 66]

Here, in FIG. 12 through FIG. 14, specifications of arranging first tothird rotating shaft parts 64, 65, and 66 to be described later atrotating parts (rotors 59) of the first to third motors 56, 57, and 58are shown.

In the specification of FIG. 12, the rotating part is configured as ahollow cylinder part 63. The hollow cylinder part 63 is configured bymaking the rotation center of the rotor 59 (see FIG. 11) concentricallydepressed. Into such a hollow cylinder part 63 (rotating part), thefirst to third rotating shaft parts 64, 65, and 66 are fitted.

In this state, rotation centers of the first to third rotating shaftparts 64, 65, and 66, and the rotating parts (rotors 59) coincide witheach other on one rotation central axis 67. Thus, the first to thirdrotating shaft parts 64, 65, and 66 become rotatable together with therotating parts (rotors 59). Accordingly, it becomes possible to transmitthe rotating states (motor output and rotational motion) of the first tothird motors 56, 57, and 58 to the outside through the first to thirdrotating shaft parts 64, 65, and 66.

In the specification of FIG. 13, the rotating part is set as an annularattaching surface 68 (see FIG. 12 and FIG. 14). The attaching surface 68is configured in such a manner that the surface 68 concentricallyspreads from the rotation central axis 67 of the rotor 59. To such anattaching surface 68 (rotating part), the first to third rotating shaftparts 64, 65, and 66 are concentrically attached. As the attachingmethod, a method using bolts for fastening, and the like can be assumed.

In FIG. 13, a bolt fastening method is shown as an example. For example,a disk-like flange part 69 is provided at an end of the first to thirdrotating shaft parts 64, 65, and 66. A plurality of fixing holes 71 (seeFIG. 12 and FIG. 14) in which bolts 70 can be inserted are formed inboth the flange part 69 and the attaching surface 68 (rotating part).The flange part 69 is brought into contact with the attaching surface(rotating part) in opposition thereto. Bolts 70 are inserted in thefixing holes 71 from the flange part 69 toward the attaching surface 68(rotating part), and are tightened, thereby fixing the flange part 69.

In this state, the rotation centers of the first to third rotating shaftparts 64, 65, and 66, and the rotating parts (rotors 59) coincide witheach other on the one rotation central axis 67. Thus, it becomespossible for the first to third rotating shaft parts 64, 65, and 66 torotate together with the rotating parts (rotors 59).

In the specification of FIG. 14, the first to third rotating shaft parts64, 65, and 66 are formed integral with the rotating parts (rotors 59).In this state, the rotation centers of the first to third rotating shaftparts 64, 65, and 66, and the rotating parts (rotors 59) coincide witheach other on the one rotation central axis 67. Thus, it becomespossible for the first to third rotating shaft parts 64, 65, and 66 torotate together with the rotating parts (rotors 59).

[First Drive Mechanism 53]

As shown in FIG. 1 through FIG. 3, the first drive mechanism 53 iscoupled to the first drive shaft part 12 a of the first roll 12. Thefirst drive mechanism 53 is configured to be able to control therotating state of the first roll 12. The first drive mechanism 53includes the first rotating shaft part 64, first motor 56, and a firstpower transmission mechanism 72.

The first rotating shaft part 64 is arranged at the rotating part of thefirst motor 56. The rotating part is configured to be able to rotatetogether with the rotor 59 (see FIG. 11). The rotation center of thefirst rotating shaft part 64, the rotation center of the rotating part,and the rotation center of the first motor 56 (rotor 59) coincide witheach other on the one rotation central axis 67. In such a state, itbecomes possible to transmit the rotating state (motor output androtational motion) of the first motor 56 to the outside through thefirst rotating shaft part 64 without incurring a loss.

In the first power transmission mechanism 72, an input part is formed onone side thereof in the power transmitting direction, and an output partis formed on the other side thereof in the power transmitting direction.The first power transmission mechanism 72 is arranged between the firstmotor 56 and the first roll 12. To the one side (input part) of thefirst power transmission mechanism 72, the first rotating shaft part 64of the first motor 56 is coupled. To the other side (output part) of thefirst power transmission mechanism 72, the first drive shaft part 12 aof the first roll 12 is coupled.

The first power transmission mechanism 72 is provided with a rigidcoupling (shaft coupling) 73, flexible coupling (shaft coupling) 74, andreducer 75. On the supporting plate 25, the rigid coupling 73 and theflexible coupling 74 are respectively arranged on both sides of thereducer 75. In the drawings, as one example, the rigid coupling 73 isarranged between the first motor 56 and the reducer 75, and the flexiblecoupling 74 is arranged between the reducer 75 and the first bearingmechanism 15.

The rigid coupling 73 is provided with a first hub flange 76, and secondhub flange 77. The first and second hub flanges 76 and 77 have shapesand sizes identical to each other.

The first hub flange 76 is provided with a disk-like first flange part78, and cylindrical first attaching part 79. The first flange part 78 isformed integral with one end of the first attaching part 79. The firstflange part 78 and the first attaching part 79 are concentricallyarranged.

The second hub flange 77 is provided with a disk-like second flange part80, and cylindrical second attaching part 81. The second flange part 80is formed integral with one end of the second attaching part 81. Thesecond flange part 80 and the second attaching part 81 areconcentrically arranged.

In this case, for example, in a state where both the flange parts 78 and80 are in contact with each other in opposition to each other, theflange parts 78 and 80 are fixed to each other by means of a pluralityof bolts (not shown). Thus, the rigid coupling 73 having the firstattaching part 79 and second attaching part 81 which outwardly protrudeon both sides is configured. To the first attaching part 79, the firstrotating shaft part 64 is coupled. The second attaching part 81 and thereducer 75 are coupled to each other by a coupling shaft 82.

The flexible coupling 74 is provided with a first hub flange 83, secondhub flange 84, and leaf spring unit 85. The first and second hub flanges83 and 84 have shapes and sizes identical to each other.

The first hub flange 83 is provided with a disk-like first flange part86, and cylindrical first attaching part 87. The first flange part 86 isformed integral with one end of the first attaching part 87. The firstflange part 86 and the first attaching part 87 are concentricallyarranged.

The second hub flange 84 is provided with a disk-like second flange part88, and cylindrical second attaching part 89. The second flange part 88is formed integral with one end of the second attaching part 89. Thesecond flange part 88 and the second attaching part 89 areconcentrically arranged.

The leaf spring unit 85 is configured by piling a plurality of leafsprings 90 one on top of another into a laminated form (see FIG. 15). Inthe drawings, as an example, the leaf spring 90 has a plate-likerectangular shape. In the leaf spring 90, a circular through-hole 90 his formed in the central part thereof. Thereby, the leaf spring 90 lightin weight and excellent in spring property is configured.

In this case, for example, both the flange parts 86 and 88 are arrangedin opposition to each other, and the leaf spring unit 85 is arrangedbetween the flange parts 86 and 88. The flange parts 86 and 88 are fixedto each other together with the leaf spring unit 85 by means of aplurality of bolts 91, washers 92, and nuts 93 (see FIG. 15). Thus, theflexible coupling 74 having the first attaching part 87 and secondattaching part 89 which outwardly protrude on both sides is configured.The first attaching part 87 and the reducer 75 are coupled to each otherby the coupling shaft 82. To the second attaching part 89, the firstdrive shaft part 12 a supported on the first bearing mechanism 15 iscoupled.

It should be noticed that in, for example, FIG. 15, an example of theflexible coupling 74 provided with a spacer 94 (intermediate shaft part)is shown. In this case, in a state where the spacer 94 is excluded, theleaf spring unit 85 is interposed between the hub flanges 83 and 84(flange parts 86 and 88) on both sides. The flange parts 86 and 88 arefixed to each other together with the leaf spring unit 85 by means ofbolts 91 and the like. Thereby, it is possible to configure the flexiblecoupling 74.

According to such a configuration, the first motor 56 is coupled to thefirst roll 12 through the first rotating shaft part 64, first powertransmission mechanism 72, and first drive shaft part 12 a. Here, thefirst motor 56 is controlled by the controller (not shown). The rotatingstate (motor output and rotational motion) of the first motor 56 istransmitted to the first drive shaft part 12 a through the firstrotating shaft part 64 and first power transmission mechanism 72. Whenthe first drive shaft part 12 a rotates, the second drive shaft part 12b rotates at the same time. Thus, it becomes possible to control therotating state (for example, number of revolutions, and rotationalspeed) of the first roll 12. In this case, the rotating state (motoroutput and rotational motion) of the first motor 56 is transmitted tothe first roll 12 in a state where the rotational speed is reduced andthe torque is increased by the first power transmission mechanism 72(reducer 75).

[Second Drive Mechanism 54]

As shown in FIG. 1 through FIG. 3, the second drive mechanism 54 iscoupled to the third drive shaft part 13 a of the second roll 13. Thesecond drive mechanism 54 is configured to be able to control therotating state of the second roll 13. The second drive mechanism 54includes the second rotating shaft part 65, second motor 57, and asecond power transmission mechanism 95.

The second rotating shaft part 65 is arranged at the rotating part ofthe second motor 57. The rotating part is configured to be able torotate together with the rotor 59 (see FIG. 11). The rotation center ofthe second rotating shaft part 65, the rotation center of the rotatingpart, and the rotation center of the second motor 57 (rotor 59) coincidewith each other on the one rotation central axis 67. In such a state, itbecomes possible to transmit the rotating state (motor output androtational motion) of the second motor 57 to the outside through thesecond rotating shaft part 65 without incurring a loss.

In the second power transmission mechanism 95, an input part is formedon one side thereof in the power transmitting direction, and an outputpart is formed on the other side thereof in the power transmittingdirection. The second power transmission mechanism 95 is arrangedbetween the second motor 57 and the second roll 13. To the one side(input part) of the second power transmission mechanism 95, the secondrotating shaft part 65 of the second motor 57 is coupled. To the otherside (output part) of the second power transmission mechanism 95, thethird drive shaft part 13 a of the second roll 13 is coupled.

The second power transmission mechanism 95 is provided with a flexiblecoupling 74. The flexible coupling 74 is arranged between the secondmotor 57 and the third bearing mechanism 17. The flexible coupling 74 isprovided with a first hub flange 83, second hub flange 84, and leafspring unit 85. The first and second hub flanges 83 and 84 have shapesand sizes identical to each other.

In the flexible coupling 74 of the second power transmission mechanism95, the first attaching part 87 and the second attaching part 89 areelongated according to the distance between the second motor 57 and thethird bearing mechanism 17. To the first attaching part 87, the secondrotating shaft part 65 is coupled. To the second attaching part 89, thethird drive shaft part 13 a supported on the third bearing mechanism 17is coupled. Configurations other than the above are identical to theflexible coupling 74 of the first power transmission mechanism 72.Accordingly, the configurations identical to the flexible coupling 74 ofthe first power transmission mechanism 72 are denoted by referencesymbols identical to those of the mechanism 72, and descriptions of themare omitted.

According to such a configuration, the second motor 57 is coupled to thesecond roll 13 through the second rotating shaft part 65, second powertransmission mechanism 95, and third drive shaft part 13 a. Here, thesecond motor 57 is controlled by the controller (not shown). Therotating state (motor output and rotational motion) of the second motor57 is transmitted to the third drive shaft part 13 a through the secondrotating shaft part 65, and second power transmission mechanism 95. Thethird drive shaft part 13 a rotates, and the fourth drive shaft part 13b rotates at the same time. Thus, it becomes possible to control therotating state (for example, number of revolutions, and rotationalspeed) of the second roll 13.

In this case, the rotating state (motor output and rotational motion) ofthe second motor 57 is transmitted to the second roll 13 as it is by thesecond power transmission mechanism 95 without the rotating state (motoroutput and rotational motion) being changed (for example, without therotational speed being reduced). As a result, it is possible to rotatethe second roll 13 with the timing identical to the rotating state(motor output and rotational motion) of the second motor 57. It shouldbe noted that, in this description, the identical timing implieshigh-level concepts such as identical number of revolutions, identicalrotational speed, identical angular speed, identical angularacceleration, and the like.

[Third Drive Mechanism 55]

As shown in FIG. 1 through FIG. 3, the third drive mechanism 55 iscoupled to the fifth drive shaft part 14 a of the third roll 14. Thethird drive mechanism 55 is configured to be able to control therotating state of the third roll 14. The third drive mechanism 55includes the third rotating shaft part 66, third motor 58, and a thirdpower transmission mechanism 96.

The third rotating shaft part 66 is arranged at the rotating part of thethird motor 58. The rotating part is configured to be able to rotatetogether with the rotor 59 (see FIG. 11). The rotation center of thethird rotating shaft part 66, the rotation center of the rotating part,and the rotation center of the third motor 58 (rotor 59) coincide witheach other on the one rotation central axis 67. In such a state, itbecomes possible to transmit the rotating state (motor output androtational motion) of the third motor 58 to the outside through thethird rotating shaft part 66 without incurring a loss.

In the third power transmission mechanism 96, an input part is formed onone side thereof in the power transmitting direction, and an output partis formed on the other side thereof in the power transmitting direction.The third power transmission mechanism 96 is arranged between the thirdmotor 58 and the third roll 14. To the one side (input part) of thethird power transmission mechanism 96, the third rotating shaft part 66of the third motor 58 is coupled. To the other side (output part) of thethird power transmission mechanism 96, the fifth drive shaft part 14 aof the third roll 14 is coupled.

The third power transmission mechanism 96 is provided with a rigidcoupling 73, flexible coupling 74, and reducer 75. In this case, thearrangement configuration of the third power transmission mechanism 96is identical to the aforementioned first power transmission mechanism72. Accordingly, configurations identical to the first powertransmission mechanism 72 are denoted by reference symbols identical tothe first power transmission mechanism 72, and descriptions of them areomitted.

In such a configuration, the third motor 58 is coupled to the third roll14 through the third rotating shaft part 66, third power transmissionmechanism 96, and fifth drive shaft part 14 a. Here, the third motor 58is controlled by the controller (not shown). The rotating state (motoroutput and rotational motion) of the third motor 58 is transmitted tothe fifth drive shaft part 14 a through the third rotating shaft part66, and third power transmission mechanism 96. The fifth drive shaftpart 14 a rotates, and the sixth drive shaft part 14 b rotates at thesame time. Thus, it becomes possible to control the rotating state (forexample, number of revolutions, and rotational speed) of the third roll14. In this case, the rotating state (motor output and rotationalmotion) of the third motor 58 is transmitted to the third roll in astate where the rotational speed is reduced and the torque is increasedby the third power transmission mechanism 96 (reducer 75).

Advantages of First Embodiment

According to this embodiment, the second power transmission mechanism 95provided with the flexible coupling 74 is arranged between the secondmotor 57 and the second roll 13. That is, the second motor 57 and thesecond roll 13 are coupled to each other through the second powertransmission mechanism 95 provided with the flexible coupling 74.Thereby, when the state where the first roll 12 is pressed against thesecond roll 13 is changed, the whole of the changed state occurring inthe second roll 13 is completely absorbed and removed by the flexiblecoupling 74.

Here, as the changed state occurring in the second roll 13, the changedstate of the rotating shaft of the second roll 13 occurring when thefirst roll 12 is moved toward or away from the second roll 13, forexample, an “angular deviation” such as an eccentricity or a deflectionangle of the second rotation central axis 13 r is assumed. Even whensuch an angular deviation (eccentricity/deflection angle) has occurred,the flexible coupling 74 (leaf spring unit 85) is elastically deformedaccording to the degree of the magnitude of the angular deviation(eccentricity/deflection angle). Thereby, the whole of the angulardeviation (eccentricity/deflection angle) is completely absorbed andremoved. Accordingly, the influence of the state where the first roll 12is pressed against the second roll 13 on the second roll, i.e., thechanged state of the second roll 13 is never transmitted to the secondmotor 57 (second rotating shaft part 65).

Furthermore, the flexible coupling 74 (leaf spring unit 85) iselastically deformed, whereby the posture of the second motor 57 (rotor59) or the second rotating shaft part 65, i.e., the posture of therotation central axis 67 is maintained constant at all times. At thesame time, the rotating state (motor output and rotational motion) ofthe second motor 57 is transmitted to the second roll 13 as it is by thesecond power transmission mechanism 95 without the rotating state (motoroutput and rotational motion) being changed (for example, without therotational speed being reduced). As a result, it is possible to rotatethe second roll 13 with the timing identical to the rotating state(motor output and rotational motion) of the second motor 57.

At this time, the torque ripples (pulsation phenomenon) of the secondmotor 57 are maintained at a level at which gear marks (horizontalstripes) do not occur. As a result, it is possible to previously preventgear marks (horizontal stripes) from occurring. Thus, it is possible tomanufacture (form) a sheet (film) without causing gear marks (horizontalstripes).

Furthermore, according to this embodiment, when viewed from a direction(longitudinal direction) parallel to the first to third rotation centralaxes 12 r, 13 r, and 14 r, the temperature regulating unit 4 is arrangedon one side of the roll unit 3 (first to third rolls 12, 13, and 14),and the drive unit 6 is arranged on the other side of the roll unit 3.Thereby, it is possible to improve the maintainability of both the units4 and 6. Furthermore, in carrying out maintenance of the piping 4 a, 4b, and 4 c of the temperature regulating unit 4, for example, even whena liquid or a coolant leaks or drops, the electric circuit or the likeof the drive unit 6 is never adversely affected.

Furthermore, according to this embodiment, regarding the second motor 57directly contributing to the rotation of the second roll 13, the numberof poles is set to 8 or more, and the number of slots is set to 15 ormore, and more desirably, the number of poles is set to 20 or more, andthe number of slots is set to 24 or more. Thereby, it is possible togenerate optimum rotational torque within the range of the practicalrotational speed (0 to 100 rpm) of the second roll 13. That is, it ispossible to realize a second motor 57 capable of generating high torqueat a low rotational speed. As a result, it is possible to previouslyprevent such a situation that formation of a sheet (film) 7 c cannot becarried out due to an overload on the second motor 57 from occurring.

[Gear Mark (Horizontal Stripes) Occurrence Test]

In FIG. 21 and FIG. 22, test results of the sheet/film manufacturingapparatus 1 of this embodiment are shown. In the test, two types ofsheet/film manufacturing apparatuses are prepared. Specifications ofboth the apparatuses are set identical to each other. In this case, asecond power transmission mechanism 95 provided with a flexible coupling74 is applied to the drive unit of one of the apparatuses, and thisapparatus is made the apparatus according to the invention as claimed inthe application concerned. A power transmission mechanism provided withno flexible coupling is applied to the drive unit of the otherapparatus, and this apparatus is made the apparatus according to theprior art. The identical operation timing was set to both theapparatuses, and then the test was carried out.

As is evident from the test results, although in the conventional sample(see FIG. 21), gear marks (horizontal stripes) occurred, in the sampleof the invention of the application (see FIG. 22), occurrence of gearmarks (horizontal stripes) was prevented. It should be noticed thatarrows in the drawings indicate the feed direction Ed of the sheet(film).

Furthermore, in such an occurrence test, a range of wavelengths T (mm)satisfying the relational expression (M≥π×D/T) to be described later isset. In the setting method, as shown in FIG. 19, the first roll 12 ismade to carry out a reciprocating motion with respect to the second roll13, whereby the thickness of the sheet (film)-like molten resin isvaried.

At this time, the pushing period on which the first roll 12 is made tocarry out a reciprocating motion is made H, and the speed(circumferential speed) of the molten resin passing through the partbetween the first roll 12 and the second roll 13 is made S. Then, in themolten resin, a periodic change appears in the flow direction of themolten resin with timing (wavelength, pitch) of P=S×H. That is, athickness variation occurs in the molten resin with timing (wavelength,pitch) of P=S×H.

In FIG. 20, an occurrence model of the thickness variation occurring inthe molten resin is shown. In the occurrence model, a result of aperiodic variation of the first roll 12 caused by periodically changingthe rotational torque of the first motor 56 between ΔTmax and ΔTmin isshown.

When the rotational torque is high (ΔTmax), the pressing amount or thefeed amount of the molten resin per unit rotational angle A becomeslarger (ΔVmax). Thereby the thickness of the molten resin increases. Thereaction force of the molten resin against the first roll 12 becomeslarger. As a result, as is evident from the locus (O₃, O₇, O₁₁, and O₁₅)of the rotation center, the first roll 12 slightly retreats(displacement or deformation).

When the rotational torque is low (ΔTmin), the pressing amount or thefeed amount of the molten resin per unit rotational angle A becomessmaller (ΔVmin). Thereby the thickness of the molten resin decreases.

The reaction force of the molten resin against the first roll 12 becomessmaller. As a result, as is evident from the locus (O₁, O₅, O₉, and O₁₃)of the rotation center, the first roll 12 slightly advances(displacement or deformation).

The inventors of the present invention has earnestly carried outresearch on the timing (wavelength, pitch) (i.e., P=S×H) of thethickness variation of the molten resin. Here, for example, while thefirst roll 12 makes one rotation, a thickness variation was made tooccur in the flow direction of the molten resin with timing (wavelength,pitch) of P (=S×H)≤5 mm. At this time, the width of the thicknessvariation is 0.3 μm or less. Such a thickness variation is absorbed andremoved by the viscoelastic characteristics of the molten resin. As aresult, it has been confirmed that it is possible to manufacture (form)a sheet (film) without causing gear marks (horizontal stripes).

Furthermore, as a result of earnest research carried out by theinventors of the present invention, it has been confirmed that when athickness variation is made to occur with timing (wavelength, pitch) ofP (=S×H)≤3 mm, gear marks (horizontal stripes) are prevented fromoccurring more effectively.

Such a thickness variation coincides with the occurrence timing of theshort-period oscillation resulting from a cogging phenomenon of thesecond motor 57. Further, such a short-period oscillation occurs withthe identical timing along the outer circumferential surface of thesecond roll rotating with the timing identical to the second motor.Then, the range of the wavelengths T (mm) to be described later can bespecified as the oscillation occurrence timing satisfying therelationship of P≤5 mm (desirably 3 mm), i.e., as a distance between twopoints identical to each other in phase.

It should be noticed that when the range of the wavelengths T (mm) to bedescribed later is P>5 mm, a “thickness variation” which is not absorbedby the viscoelastic characteristics of the molten resin occurs. Forexample, when P=13 mm, the width of the thickness variation becomes 10μm. In this case, occurrence of gear marks (horizontal stripes) cannotbe prevented and, as a result, gear marks remain on the manufactured(formed) sheet (film).

[Specification of Second Motor 57 Based on Characteristics of MoltenResin]

After the startup of the sheet/film manufacturing apparatus, and at theprevious step before manufacturing (forming) of a completed product,there is sometimes a case where gear marks (horizontal stripes) occur onthe surface of the sheet (film) 7 c (see FIG. 1). At this time, evenwhen, for example, the forming conditions or operation conditions areadjusted, occurrence of the gear marks (horizontal stripes) cannot beprevented from occurring.

In this case, according to the earnest technical research carried out bythe inventors of the present invention, when a variation has been givento the molten resin fed along the roll unit 3 with a specific period, ithas been made clear that regarding the pitch of the thickness variationoccurring on the sheet (film), in other words, a short-periodoscillation having a wavelength of 5 mm or less on the sheet (film), thevariation is absorbed by the viscoelastic characteristics of the moltenresin, and the influence of the variation of the molten resin does notappear.

Thereby, it can be seen that when the number of times of short-periodoscillations occurring while the roll makes one rotation is equal to orgreater than a value obtained by dividing the outer circumferentiallength by the wavelength 5 mm, the short-period oscillations have noinfluence on the molten resin.

The cogging phenomena occur the number of times corresponding to theleast common multiple of the number of poles and the number of slotswhile the motor (rotor) makes one rotation.

Thus, letting the least common multiple of the number of poles and thenumber of slots of the second motor 57 be M, the diameter of the secondroll 13 be D (mm), and the aforementioned wavelength be T (mm), thefollowing relational expression is established.M=π×D/T (π: circular constant)

As described above, it has turned out that with respect to theshort-period oscillations having a wavelength of 5 mm or less (T≤5) onthe sheet (film), the variation is absorbed by the viscoelasticcharacteristics of the molten resin, and no influence of the variationof the molten resin appears. Thus the least common multiple M of thenumber of poles and the number of slots of the second motor 57 isconfigured to satisfy the following relational expression.M≥π×D/T (T=5)

That is, M≥π×D/5

Thereby, torque ripples (pulsation phenomenon) based on the coggingphenomena are absorbed by the viscoelastic characteristics of the moltenresin. As a result, it is possible to manufacture (form) a sheet (film)without causing gear marks (horizontal stripes).

[Sheet/Film Manufacturing Apparatus 1 According to Second Embodiment(FIG. 4 through FIG. 6)]

In the second motor 57 of the drive unit 6 (second drive mechanism 54),in order to make the second motor 57 generate high torque at a lowrotational speed, the number of poles is increased. With the increase inthe number of poles, the external dimensions of the second motor becomelarger. At this time, depending on the degree of the increase in thenumber of poles, the external dimensions of the second motor 57 becomeslarger than the diameter of the second roll 13 in some cases. Then, itbecomes difficult to arrange the second motor 57 between the first motor56 and the third motor 58.

More specifically, for example, when the first roll 12 is pressedagainst the second roll 13 in order to carry out thickness adjustment ofthe formed product or disturbance correction, the first motor 56 ismoved toward the second motor 57 following the first roll 12. At thistime, depending on the degree of the diameter of the second roll 13 oron the degree of the external dimensions of the second motor 57, thefirst motor 56 comes into contact with the second motor 57. Then, itbecomes impossible to carry out thickness adjustment of the formedproduct or disturbance correction. As a result, it becomes impossible tomaintain the quality of the sheet (film) as the completed productconstant.

As the measure to solve such a problem, for example, it is advisable toarrange the second motor 57 at a position separate from the first motor56. As an example of such an arrangement method, a first method ofmaking the space between the first motor 56 and the first roll 12smaller than the space between the second motor 57 and the second roll13, or a second method of making the space between the second motor 57and the second roll 13 larger than the space between the first motor 56and the first roll 12 can be assumed.

Further, as described above, the first bearing mechanism 15, the thirdbearing mechanism 17, and the fifth bearing mechanism 19 are linearlylined up in a direction perpendicular to the first to third rotationcentral axes 12 r, 13 r, and 14 r. Thus, on the basis of the bearingmechanisms 15, 17, and 19, the aforementioned arrangement method isconsidered.

For example, it is possible to assume a first method of making the spacebetween the first motor 56 and the first bearing mechanism 15 smallerthan the space between the second motor 57 and the third bearingmechanism 17, or a second method of making the space between the secondmotor 57 and the third bearing mechanism 17 larger than the spacebetween the first motor 56 and the first bearing mechanism 15.

In FIG. 4, as an example, an arrangement associated with the firstmethod described above is shown. That is, the space between the firstmotor 56 and the first roll 12 (first bearing mechanism 15) is setsmaller than the space between the second motor 57 and the second roll13 (third bearing mechanism 17). It should be noted that the spacebetween the first motor 56 and the first roll 12 (first bearingmechanism 15), and the space between the third motor 58 and the thirdroll 14 (fifth bearing mechanism 19) are set to spaces identical to eachother. Further, the first and third power transmission mechanisms 72 and96 which are respectively arranged between the first and third motors 56and 58, and the first and third rolls 12 and 14 are identical to thefirst embodiment (see FIG. 2 and FIG. 3), and hence the configurationsidentical to the first embodiment are denoted by reference symbolsidentical to the first embodiment, and descriptions of them are omitted.

Here, between the second motor 57 and the second roll 13 (third bearingmechanism 17), the second power transmission mechanism 95 is arranged.The second power transmission mechanism 95 is provided with two flexiblecouplings 74, and spacer 94 (intermediate shaft part). The total lengthof the spacer 94 is set according to the distance between the secondmotor 57 and the second roll 13 (third bearing mechanism 17). Forexample, by adjusting length of the intermediate part 94 p of the spacer94 to be described later, it is possible to arrange the second powertransmission mechanism 95 between the second motor 57 and the secondroll 13 (third bearing mechanism 17) with high accuracy.

As shown in FIG. 15, the spacer 94 includes a cylindrical intermediatepart 94 p, disk-like first flange part 97, and disk-like second flangepart 98. The first flange part 97 is formed concentrically integral withone end of the intermediate part 94 p. The second flange part 98 isformed concentrically integral with the other end of the intermediatepart 94 p. The first flange part 97 and the second flange part 98 arearranged in parallel with each other and in opposition to each other.

Furthermore, the first flange part 97 and the second flange part 98 haveshapes and sizes identical to each other. In this case, the first andsecond flange parts 97 and 98 of the spacer 94, and the first and secondflange parts 86 and 88 of the first and second flexible couplings 74have shapes and sizes identical to each other.

The two flexible couplings 74 are respectively provided on both sides ofthe spacer 94. Between the spacer 94 (first flange part 97) and thesecond motor (first rotating shaft part 65), the first flexible coupling74 (one of the two flexible couplings 74) is arranged. Between thespacer 94 (second flange part 98) and the second roll 13 (third driveshaft part 13 a), the second flexible coupling 74 (the other of the twoflexible couplings 74) is arranged.

The first flexible coupling 74 (one of the two flexible couplings 74) isconfigured by being provided with the aforementioned leaf spring unit 85between the aforementioned first hub flange 83 and the aforementionedspacer 94 (first flange part 97). In this case, the leaf spring unit 85is arranged between the first flange part 86 of the first hub flange 83and the first flange part 97 of the spacer 94. The flange parts 86 and97 are fixed to each other by means of a plurality of bolts 91 and thelike. Thus, one of the flexible couplings 74 can be configured.

The second flexible coupling (the other of the two flexible couplings74) is configured by being provided with the aforementioned leaf springunit 85 between the aforementioned second hub flange 84 and theaforementioned spacer 94 (second flange part 98). In this case, the leafspring unit 85 is arranged between the second flange part 88 of thesecond hub flange 84 and the second flange part 98 of the spacer 94. Theflange parts 88 and 98 are fixed to each other by means of a pluralityof bolts 91 and the like. Thus, the second flexible coupling 74 (theother of the two flexible couplings 74) can be configured.

Here, in FIG. 15, as an example, the intermediate shaft part (spacer) 94is constituted of one integrated shaft member (i.e., intermediate part94 p). However, the configuration of such an intermediate shaft part(spacer) 94 is not limited to the above. For example, one intermediateshaft part (spacer) 94 may be constituted of a member formed by couplinga plurality of shaft members (intermediate parts 94 p) to each other.

More specifically, a plurality of shaft members (intermediate parts 94p) are prepared, and these shaft members (intermediate parts 94 p) areflexibly coupled to each other by the first flexible coupling 74. Thus,it is possible to configure one intermediate shaft part (spacer) 94 inwhich a plurality of shaft members (intermediate parts 94 p) are coupledto each other.

According to such a configuration, the changed state of the rotatingshaft of the second roll 13 occurring when the first roll 12 is movedtoward or away from the second roll 13, for example, an “angulardeviation” such as an eccentricity or a deflection angle of the secondrotation central axis 13 r is absorbed and removed by the intermediateshaft part (spacer) 94 or the intermediate part 94 p being inclined withthe one shaft coupling (shaft coupling 74 closer to the second motor 57)used as a base point. Thereby, the posture of the rotating shaft(rotation center) of the second motor 57 is maintained constant at alltimes.

It should be noted that in FIG. 5 and FIG. 6, a sheet/film manufacturingapparatus 1 according to another configuration of the aforementionedsecond embodiment is shown. The first and third power transmissionmechanisms 72 and 96 have configurations identical to the aforementionedsecond power transmission mechanism 95. The first and third powertransmission mechanisms 72 and 96 are configured by making the length ofthe spacer 94 (intermediate part 94 p) of the second power transmissionmechanism 95 short. According to such a configuration, it is possible tomanufacture (form) a sheet (film) more securely without causing gearmarks (horizontal stripes).

Advantages of Second Embodiment

As the space between the first motor 56 and the first roll 12 (firstbearing mechanism 15) becomes longer, not only the torsional rigidity ismade lower, but also the weight (mass) is made heavier correspondinglyto the elongated amount of space.

Then, as described previously, there is a possibility of theresponsibility or the followability of the first roll 12 being lowered.

However, as described in this embodiment, the space between the firstmotor 56 and the first roll 12 (first bearing mechanism 15) is setsmaller than the space between the second motor 57 and the second roll13 (third bearing mechanism 17). Then, it is possible to maintain orimprove the torsional rigidity, and reduce the weight (mass)correspondingly to the shortened amount of space.

Thereby, it is possible to improve the responsibility or thefollowability of the first roll 12 or maintain the responsibility or thefollowability thereof constant. As a result, it is possible to maintainthe quality of the sheet (film) as the completed product constant. Itshould be noted that other advantages are identical to the advantages ofthe aforementioned first embodiment, and hence descriptions of them areomitted.

[Sheet/Film Manufacturing Apparatus 1 According to Third Embodiment(FIG. 16 and FIG. 17)]

This embodiment is an improvement of the aforementioned secondembodiment (FIG. 4 through FIG. 6). As the first and third powertransmission mechanisms 72 and 96, commercially available link-typecouplings 99 (Schmidt couplings) are applied. Although such a coupling99 is applicable to any of the first to third power transmissionmechanisms 72, 95, and 96, hereinafter a case where the couplings 99 areapplied to the first and third power transmission mechanisms 72 and 96will be described.

As shown in FIG. 16 and FIG. 17, the couplings 99 applied to the firstand third power transmission mechanisms 72 and 96 have configurationsidentical to each other. The coupling 99 includes a first disk 100,second disk 101, intermediate disk 102, and link mechanisms (first tofourth links 103 to 106, first to fourth pins 107 to 110). The coupling99 is arranged/configured between a first coupling part 111 and a secondcoupling part 112.

The coupling parts 111, and 112 on both sides of the first powertransmission mechanism 72 are respectively attached to the firstrotating shaft part 64 of the first motor 56 and the first drive shaftpart 12 a of the first roll 12. That is, the first disk 100 is coupledto the first rotating shaft part 64 through the coupling part 111.Furthermore, the second disk 101 is coupled to the first drive shaftpart 12 a through the coupling part 112.

The coupling parts 111, and 112 on both sides of the third powertransmission mechanism 96 are respectively attached to the thirdrotating shaft part 66 of the third motor 58 and the fifth drive shaftpart 14 a of the third roll 14. That is, the first disk 100 is coupledto the third rotating shaft part 66 through the coupling part 111.Furthermore, the second disk 101 is coupled to the fifth drive shaftpart 14 a through the coupling part 112.

The first disk 100, second disk 101, and intermediate disk 102 haveshapes and sizes identical to each other. The first disk 100, the seconddisk 101, and the intermediate disk 102 have a hollow disk-like shape.The first disk 100, the second disk 101, and the intermediate disk 102are arranged in parallel with each other and in opposition to eachother. The intermediate disk 102 is arranged between the first disk 100and the second disk 101.

On both sides of the intermediate disk 102, first and secondintermediate surfaces 102 a and 102 b opposed to each other in parallelwith each other are configured. The first disk 100 is arranged inopposition to the first intermediate surface 102 a of the intermediatedisk 102. The first disk 100 has a first surface 100 a opposed to thefirst intermediate surface 102 a in parallel with each other.

A link mechanism is configured between the first surface 100 a and thefirst intermediate surface 102 a. That is, on the first surface 100 a,two first pins 107 are provided. The two first pins 107 protrude towardthe first intermediate surface 102 a in parallel with each other. On thefirst intermediate surface 102 a, two second pins 108 are provided. Thetwo second pins 108 protrude toward the first surface 100 a in parallelwith each other.

The first pins 107 and the second pins 108 are coupled to each otherthrough first and second links 103 and 104. In each of the first andsecond links 103 and 104, two coupling holes 113 and 114 are formed. Inthe coupling holes 113 and 114, bearings (not shown) are accommodated.In each of the first and second links 103 and 104, the first pin 107 isrotatably coupled to the one coupling hole 113. The second pin 108 isrotatably coupled to the other coupling hole 114.

On the other hand, the second disk 101 is arranged in opposition to thesecond intermediate surface 102 b of the intermediate disk 102. Thesecond disk 101 has a second surface 101 a opposed to the secondintermediate surface 102 b in parallel with each other.

A link mechanism is configured between the second surface 101 a and thesecond intermediate surface 102 b. That is, on the second intermediatesurface 102 b, two third pins 109 are provided. The two third pins 109protrude toward the second surface 101 a in parallel with each other. Onthe second surface 101 a, two fourth pins 110 are provided. The twofourth pins 110 protrude toward the second intermediate surface 102 b inparallel with each other.

The third pins 109 and the fourth pins 110 are coupled to each otherthrough the third and fourth links 105 and 106. In each of the third andfourth links, two coupling holes 115 and 116 are formed. In the couplingholes 115 and 116, bearings (not shown) are accommodated. In each of thethird and fourth links 105 and 106, the third pin 109 is rotatablycoupled to the one coupling hole 115. The fourth pin 110 is rotatablycoupled to the other coupling hole 116.

It should be noted that when the aforementioned coupling 99 is appliedto the second power transmission mechanism 95, the first disk 100 iscoupled to the second rotating shaft part 65 through a coupling part111, and the second disk 101 is coupled to the third drive shaft part 13a through a coupling part 112. It is needless to say that, thereby,advantages identical to the first embodiment can be obtained.

Advantages of Third Embodiment

According to this embodiment, the rotating states (motor output androtational motion) of the first and third motors 56 and 58 aretransmitted from the first and third rotating shaft parts 64 and 66 tothe first disks 100 through the coupling parts 111. At this time, therotational motion of the first disks 100 is transmitted from the firstand second links 103 and 104 to the intermediate disks 102, and isthereafter transmitted from the third and fourth links 105 and 106 tothe second disks 101. At this time, the rotational motion of the seconddisks 101 is transmitted from the coupling parts 112 to the first andthird rolls 12 and 14 through the first and fifth drive shaft parts 12 aand 14 a. Thus, it is possible to rotate the first and third rolls 12and 14 with the timing identical to the rotating states (motor outputand rotational motion) of the first and third motors 56 and 58.

Furthermore, the changed state of the second roll 13 occurring when thefirst roll 12 is moved toward or away from the second roll 13 isabsorbed and removed by the aforementioned link mechanisms. Thereby, itis possible to maintain the postures of the first and third rotatingshaft parts 64 and 66 constant at all times. It should be noted thatother configurations are identical to the second embodiment, and henceconfigurations identical to the second embodiment are denoted byreference symbols identical to the second embodiment, and descriptionsof them are omitted. Furthermore, the advantages other than the aboveare identical to the aforementioned first and second embodiments, andhence descriptions of them are omitted.

[Sheet/Film Manufacturing Apparatus 1 According to Fourth Embodiment(FIG. 18)]

This embodiment is an improvement of the aforementioned secondembodiment (FIG. 4 through FIG. 6). As the first and third powertransmission mechanisms 72 and 96, commercially available ball joints117 are applied. A ball joint 117 is configured by being provided withjoint mechanisms (not shown) covered with rubber boots 119 on both sidesof a shaft 118. The joint mechanism is, although not particularly shown,provided with a socket on which a spherical sliding surface is formed,and metallic ball rotatable along the socket (sliding surface). Further,to the metallic balls, the first and third rotating shaft parts 64 and66 of the first and third motors 56 and 58, and the first drive shaftpart 12 a and fifth drive shaft part 14 a of the first and third rolls12 and 14 are coupled.

Advantages of Fourth Embodiment

According to this embodiment, the metallic balls rotate and turn alongthe sockets (sliding surfaces), whereby it is possible to rotate thefirst and third rolls 12 and 14 with the timing identical to therotating states (motor output and rotational motion) of the first andthird motors 56 and 58. It should be noted that other configurations areidentical to the second embodiment, and hence configurations identicalto the second embodiment are denoted by reference symbols identical tothe second embodiment, and descriptions of them are omitted.Furthermore, the advantages of this embodiment are identical to theaforementioned first and second embodiments, and hence descriptions ofthem are omitted.

It should be noted that, here, as an example, although a specificationin which ball joints 117 are applied as the shaft couplings of the firstand third power transmission mechanisms 72 and 96 has been described,the specification is not limited to the above, and such a ball joint 117may be applied as the shaft coupling of the aforementioned second powertransmission mechanism 95. For example, in the aforementioned embodimentassociated with FIG. 2, although the flexible coupling 74 is applied asthe shaft coupling of the second power transmission mechanism 95, inplace of the flexible coupling 74, the ball joint 117 is applied.

[Sheet/Film Manufacturing Apparatus 1 According to Fifth Embodiment(FIG. 23 through FIG. 27)]

FIG. 23 to FIG. 27 each show a concrete structure of a sheet/filmmanufacturing apparatus 1 (sheet/film forming roll apparatus) accordingto modifications of the first to fourth embodiments described above.Note here that the first and second rolls 12 and 13 according to thefirst to fourth embodiments comprise cylindrical and mirror-finishedfirst and second transcription surfaces 12 s and 13 s, whereas in thisembodiment, preset patterns P1 and P2 (see FIG. 26) are formed oncylindrical first and second transcription surfaces 12 s and 13 s of thefirst and second rolls 12 and 13.

As the patterns P1 and P2, for example, a regular specification in whicha pattern layout is regularly repeated along the shaft direction and anirregular specification in which a pattern layout is repeatedirregularly along the shaft direction are considered. Furthermore, anentire specification in which the pattern layout is formed on over theentire roll surface and a local specification in which the patternlayout is formed only on a section of the roll surface are considered.In addition, a single-type specification in which the pattern layout isformed by one type of uneven shape (outline) and a multi-typespecification in which the pattern layout is formed by a plurality oftypes of uneven shapes (outline) are considered.

Here, a specification of combination of various specifications describedabove can be considered, which is, for example, a specificationcomprising such a surface configuration (outline) that a recess (orprojection) is laid out on a section of a roll surface while the othersection is flat.

In this embodiment, a direction along the first rotation central axis 12r is defined as a shaft direction 12 r, a direction along the secondrotation central axis 13 r is defined as a shaft direction 13 r and adirection along a third rotation central axis 14 r is defined as a shaftdirection 14 r.

The drawings show an example in which a first pattern P1 is formed onthe first transcription surface 12 s of the first roll 12 bycontinuously arranging a plurality of circumferentially continuouscircular grooves 12 g along the shaft direction 12 r. Each circulargroove 12 g is formed by recessing of the first transcription surface 12s circularly along its circumferential direction. In other words, aplurality of projections 12 t projecting in a tapered manner towards theradial direction perpendicular to the shaft direction are formed on thefirst transcription surface 12 s.

On the other hand, a second pattern P2 is formed on the secondtranscription surface 13 s of the second roll 13 by intermittentlyarranging a plurality of circumferentially continuous rectangulargrooves 13 g along the shaft direction 13 r. Each rectangular groove 13g is formed by recessing of the second transcription surface 13 srectangularly along its circumferential direction. The rectangulargrooves 13 g are formed so that the pitch thereof along the shaftdirection 13 r coincides with the pitch of the projection 12 t along theshaft direction 12 r.

In the initial setting of the apparatus, the positions of the first roll12 and the second roll 13 along the shaft directions 12 r and 13 r areadjusted. Here, at the contact point G1 between the first roll 12 andthe second roll 13, the projections 12 t and the rectangular grooves 13g oppose respectively one by one with each other. In this state, thefirst and second rolls 12 and 13 are rotated. Thus, on the molten resin7 a continuously fed out from the discharge unit 2, the first patternsP1 and the second patterns P2 are transcribed onto respective surfaceswhile passing the contact point G1.

FIG. 26 shows, as an example, a partial cross section of the moltenresin 7 b at the time of passing the contact point G1. The firstpatterns P1 is transcribed on a surface 7 s-1 of the molten resin 7 band the second patterns P2 is transcribed on a rear surface 7 s-2. Atthis time, no displacement is created between these patterns P1 and P2on respective surfaces of the sheet (film) with relative to each other.

On the other hand, in some cases, the roll 12 and both 13 may be shiftedrelatively to the shaft directions 12 r and 13 r while the apparatusbeing driven. In this case, the shifting appears as displacement betweenthe patterns P1 and P2 on the respective surfaces of the sheet (film).Here, if the amount of the displacement between the patterns P1 and P2exceeds a certain degree, a sheet (film) of a predetermined qualitycannot be manufactured (formed).

Under these circumstances, the sheet/film forming roll apparatus of thisembodiment is configured to be able to adjust the positions of the tworolls 12 and 13 (the patterns P1 and P2) along the shaft directions 12 rand 13 r, respectively. The timing for adjusting the positions of theshaft directions 12 r and 13 r is assumed to be, for example, at theinitial setting of the apparatus (that is, before the start oftranscription of patterns P1 and P2) or during the driving of theapparatus (that is, while transcribing the patterns P1 and P2).

The sheet/film forming roll apparatus comprises a shaft directionsupporting mechanism 120 and an axial position adjusting mechanism 121in addition to the structure of each of the first to fourth embodiments.The shaft direction supporting mechanism 120 is configured to be able tosupport the second roll 13 along the shaft direction (the directionalong the second rotation central axis 13 r) while the second roll 13being rotatable. The axial position adjusting mechanism 121 moves thesecond roll 13 in the shaft direction 13 r along the first roll 12 bymoving the shaft direction supporting mechanism 120 in the shaftdirection 13 r. A concrete description thereof will now be provided.

[Shaft Direction Supporting Mechanism 120]

As shown in FIG. 23 to FIG. 25 and FIG. 27, the shaft directionsupporting mechanism 120 is configured to be able to support of thebearing parts (a third drive-shaft part 13 a and a fourth drive-shaftpart 13 b) of the second roll 13. In an example shown in the drawing,the third drive-shaft part 13 a is supported rotatably by the shaftdirection supporting mechanism 120 so as not to shift in the shaftdirection 13 r. Furthermore, as the shaft direction supporting mechanism120, for example, a thrust-bearing unit or an angular bearing unit canbe assumed. In an example shown in the drawing, a thrust-bearing unit(see FIG. 27) is applied as the shaft direction supporting mechanism120.

The thrust-bearing unit (shaft direction supporting mechanism) 120comprises an annular stepped portion 122, a bearing case 123, two thrustbearings (a first thrust bearing 124 and a second thrust bearing 125)and a fastening tool 126. The annular stepped portion 122 refers to anannually remaining portion in the state where a portion of the thirddrive-shaft part 13 a is reduced in diameter. This portion (the annularstepped section 122) is configured to be able to contact, for example, afourth bearing washer 125 b of the second thrust bearing 125, which willbe described later, when the third drive-shaft part 13 a is inserted tothe thrust-bearing unit 120 along the shaft directions 13 r.

The bearing housing 123 is configured to be movable in the shaftdirections 13 r by the axial position adjusting mechanism 121 (adjustingplate 127), which will be described later. The bearing housing 123comprises a hollow annular stopper 123 p at a central portion thereof.The stopper 123 p is configured to allow the third drive-shaft part 13 aof the second roll 13 to pass therethrough.

The bearing housing 123 is configured so that the first thrust bearing124 can be disposed on one side of the stopper 123 p along the shaftdirection 13 r. The bearing housing 123 is configured so that the secondthrust bearing 125 can be disposed on the other side of the stopper 123p along the shaft direction 13 r. The first and second thrust bearings124 and 125 are located to oppose parallel to each other in the statewhere the first and second thrust bearings 124 and 125 are arranged atboth sides of the stopper 125 p, respectively.

The first thrust bearing 124 comprises a pair of bearing washers (afirst bearing washer 124 a and a second bearing washer 124 b) disposedto oppose each other, and a plurality of rolling members 124 c (forexample, balls or rollers) displaced rollably along between the bearingwashers 124 a and 124 b. With this structure, both of the bearingwashers 124 a and 124 b can be rotated with relative to each other asthe rolling members 124 c roll along between the bearing washers 124 aand 124 b.

The second thrust bearing 125 comprises a pair of bearing washers (athird bearing washer 125 a and a fourth bearing washer 125 b) disposedto oppose each other, and a plurality of rolling members 125 c (forexample, balls or rollers) disposed rollably along between the bearingwashers 125 a and 125 b. With this structure, both of the bearingwashers 125 a and 125 b can be rotated with relative to each other asthe rolling members 125 c roll along between the bearing washers 125 aand 125 b.

In this case, the second bearing washer 124 b and the third bearingwasher 125 a located to be in contact with the stopper 123 p in thestate where the first and second thrust bearings 124 and 125 arearranged on both sides of the stopper 123 p, respectively. Here, thethird drive-shaft part 13 a is inserted from the second thrust bearing125 (the bearing washers 125 a and 125 b) through to the first thrustbearing 124 (the bearing washers 124 a and 124 b). The annular steppedsection 122 of the third drive-shaft part 13 a is brought into contactwith the fourth bearing washer 125 b of the second thrust bearing 125.

In this state, the fastening tool 126 (for example, nut) is mounted toface the first thrust bearing 124 (the bearing washers 124 a and 124 b).For example, the fastening tool (nut) 126 is fastened along with athread portion (not shown) formed on the third drive-shaft part 13 a soas to bring the tool into contact with the first bearing washer 124 a ofthe first thrust bearing 124.

At this time, the first and second thrust bearings 124 and 125 on therespective sides of the stopper 123 p are interposed between the annularstepped section 122 and the fastening tool (nut) 126. At the same time,the stopper 123 p is interposed between the second bearing washer 124 band the third bearing washer 125 a. Thus, the shaft direction supportingmechanism 120 is established, which can support the second roll 13 alongthe shaft directions 13 r while maintaining the second roll 13rotatable.

[Axial Position Adjusting Mechanism 121]

As shown in FIG. 23 to FIG. 25, the axial position adjusting mechanism121 comprises an adjusting plate 127, a linear guide 128, a hydraulicactuator 129 and a preload mechanism 130. On the adjusting plate 127,the second drive mechanism 54 (a second rotating shaft part 65, a secondmotor 57 and a second power transmission device 95) and the shaftdirection supporting mechanism 120 (the bearing housing 123) are mountedintegrally as one body, and the adjusting plate 127 is configured to bemovable along the shaft direction 13 r.

The linear guide 128 is formed between the base 30 and the adjustingplate 127. The linear guide 128 comprises a guide rail 128 a disposed onthe base 30 and a slider 128 b disposed on the adjusting plate 127. Theguide rail 128 a is formed along the shaft direction 13 r. The slider128 b is configured to be movable along the guide rail 128 a. Thus, theadjusting plate 127 can be moved by the hydraulic actuator 129, whichwill be described later, forward as indicated by an arrow S1 andbackward as indicated by an arrow S2 along the shaft direction 13 r.

The hydraulic actuator 129 is configured to be able to apply thepressing force and traction force to the adjusting plate 127 as theoperator manipulates a manipulating portion 131. The drawings shows anexample in which the actuator 129 comprises a cylinder 132, a piston133, a piston rod 134, a measuring instrument 135 that can measure theposition of the piston 133, a servo motor 136 and a bidirectional pump137.

The piston 133 is accommodated in the cylinder 132. The piston 133 isconfigured to be reciprocatable along the cylinder 132. The cylinder 132includes an advancing chamber 132 a and a retreating chamber 132 b onrespective sides of the piston 133. The piston rod 134 is formed topenetrate the cylinder 132 from the retreat chamber 132 b. A proximalend of the piston rod 134 is connected to the piston 133. A distal endof the piston rod 134 is connected to the adjusting plate 127.

Here, as operator manipulates the manipulating portion 131, themanipulating portion 131 controls the servo motor 136 based onmeasurement data (for example, position information of the piston 133)from the measuring instrument 135. The servo motor 136 drives thebidirectional pump 137. At this time, the pressure to be applied on theadvancing chamber 132 a or the retreating chamber 132 b is selectivelycontrolled.

For example, when pressurizing the advancing chamber 132 a, oil issupplied to the advancing chamber 132 a from the bidirectional pump 137.Therefore, the oil pressure in the advancing chamber 132 a rises topress the piston 133. Thus, the piston rod 134 moves forward to apply apressing force onto the adjusting plate 127. Thereby, the adjustingplate 127 can be advanced in the direction indicated by arrow S1. Atthis time, the shaft direction supporting mechanism 120 (bearing housing123) moves forward in the direction indicated by arrow S1 together withthe adjusting plate 127. The third drive-shaft part 13 a also moves inthe direction S1. In this way, the second roll 13 can be moved(forwards) along the shaft direction 13 r.

On the other hand, when pressurizing the retreating chamber 132 b, oilis supplied to the retreating chamber 132 b from the bidirectional pump137. Thus, the oil pressure in the retreat chamber 132 b rises.Therefore, the piston 133 is suctioned to retreat the piston rod 134.Thus, the traction force is applied on the adjusting plate 127. Thereby,the adjusting plate 127 can be moved backward in the direction S2. Atthis time, the shaft direction supporting mechanism 120 (bearing housing123) retreats in the direction indicated by arrow S2 together with theadjusting plate 127. The third drive-shaft part 13 a also moves in thesame direction S2. In this way, the second roll 13 can be moved(backward) along the shaft direction 13 r.

Moreover, the axial position adjusting mechanism 121 comprises thepreload mechanism 130 which applies a given pressure on the hydraulicactuator 129. The preload mechanism 130 is formed between the base 30and the adjusting plate 127. As the preload mechanism 130, for example,a spring, an air cylinder or the like can be assumed. The drawings showan example in which a spring is applied to the preload mechanism 130.One end of the spring (preload mechanism) 130 is attached to theadjusting plate 127 via an attaching portion 138, and the other end isfixed to the base 30 via a fixing portion 139.

In this case, the adjusting plate 127 is maintained in the state wherethe pressing force from the spring (preload mechanism) 130 is acting atall times. For example, the adjusting plate 127 is always pressurized inthe direction indicated by arrow S2. This pressure acts on the piston133 via the piston rod 134 from the adjusting plate 127. Thus, theoperation of the actuator 129, that is, the reciprocation of the pistonrod 134 (piston 133) can be performed at high response. In this way,movement of the adjusting plate 127, i.e., (forward or backward)movement of the second roll 13 can be carried out with high precision.

[Advantage and Effect of the Fifth Embodiment]

According to this embodiment, a cross section of the sheet (film) 7 c(see FIG. 23) is visually observed, for example, at the initial settingof the apparatus (before the start of transcribing the patterns P1 andP2) or during the apparatus being driven (during the transcription ofthe patterns P1 and P2). If a displacement is observed between thepatterns on the two surfaces, the operator manipulates the manipulatingportion 131 without stopping the rotation of the motors 56, 57, and 58(that is, rolls 12, 13, and 14). The manipulating portion 131 controlsthe servo motor 136 based on the measurement data (the positioninformation of the piston 133) from the measuring instrument 135. Then,the oil is supplied to the advancing chamber 132 a or the retreatingchamber 132 b from the bidirectional pump 137.

At this time, the piston rod 134 moves forward or backward together withthe piston 133. The adjusting plate 127 moves forward or backward alongthe shaft direction 13 r. Along with the adjusting plate 127, the shaftdirection supporting mechanism 120 (the bearing housing 123) movesforward or backward. The third drive-shaft part 13 a also moves in thesame direction.

Thus, the second roll 13 can be moved (forward or backward) along theshaft direction 13 r (the first roll 12). As a result, it is possible toadjust the positions of the patterns P1 and P2 on both of the first roll12 and the second roll 13 along the shaft directions 12 r and 13 r,respectively. Therefore, displacement between the patterns P1 and P2 canbe eliminated. In this way, a sheet (film) of a predetermined quality onwhich the patterns P1 and P2 are transcribed on the respective surfaceswithout displacement can be manufactured (formed).

According to this embodiment, the preload mechanism 130 which appliespressure on the hydraulic actuator 129 is provided. The pressing forceof the preload mechanism 130 is acting on the piston 133 from the pistonrod 134 at all times. Thus, the reciprocation of the piston rod 134 (thepiston 133) can be performed with high response. As a result, the secondroll 13 can be moved (forward or backward) with high precision. In thisway, the positions of the patterns P1 and P2 along the shaft directions12 r and 13 r, respectively, can be adjusted with high precision. Theother advantages and effects are similar to those of the first to fourthembodiments described above, and therefore the explanations thereof willbe omitted.

[Modification (1) of the Fifth Embodiment]

The fifth embodiment described above is presumed based on thespecification that the patterns P1 and P2 are formed on the first andsecond rolls 12 and 13, respectively, but in place, such a specificationthat the patterns are formed on the second roll 12 and the third roll14, respectively, can fall within the technical scope of the presentinvention. In this case, preset patterns are formed on a secondtranscription surface 13 s of the second roll 13 and a feeding surface14 s of the third roll 14, respectively. A first transcription surface12 s of the first roll 12 is mirror-finished.

According to this modification, the molten resin 7 a is supplied, forexample, between the first roll 12 and the second roll 13 from thedischarge unit 2 (T die 9). The molten resin 7 b having passed throughbetween the first roll 12 and the second rolls 13 (contact point G1 (seeFIG. 1)) is conveyed along the second roll 13 and then allowed to passthe second roll 13 and the third roll 14. At this time, a sheet (film) 7c on both surfaces of which the patterns are transcribed respectively isformed.

Note that the expression “the molten resin 7 b passes the second roll 13and the third roll 14” covers a concept of both cases, namely,simultaneous pattern transcription and individual pattern transcription.The simultaneous pattern transcription is applied to the first to fifthembodiments, in which when the molten resin 7 b passes through betweenthe second roll 13 and the third roll 14, which face each other to berotatable, patterns are simultaneously transcribed on both surfaces ofthe molten resin 7 b, respectively.

The individual pattern transcription is carried out by a structurecomprising the second roll 13 and a pressing roll (not shown) which faceeach other and are rotatable, and the third roll 14 and a pressing roll(not shown) which face each other and are rotatable. According to thisstructure, when the molten resin 7 b passes through between the secondroll 13 and the pressing roll, a pattern is transcribed on the surfaceof the molten resin 7 b. Then, when the molten resin 7 b passes throughbetween the third roll 14 and the pressing roll, a pattern istranscribed on the rear surface of the molten resin 7 b.

Here, displacement between the patterns on these surfaces is found whilevisual observation of the cross section of the sheet (film) 7 c (seeFIG. 23), the operator manipulate the manipulating portion 131. At thistime, the second roll 13 can be moved (forward or backward) along theshaft direction 13 r (third roll 14) by the actuator 129. As a result,the positions of the patterns on the second roll 13 and the third roll14 along the shaft directions 13 r and 14 r, respectively, can be bothadjusted. The other advantages and effects are similar to those of thefirst to fourth embodiments described above, and therefore theexplanations thereof will be omitted.

[Modification (2) of the Fifth Embodiment]

The fifth embodiment and Modification (1) described above are presumedbased on the specification that the displacement between the patterns onthe surfaces are confirmed by visual observation on the cross section ofthe sheet (film) 7 c, but in place, such a specification that thedisplacement between patterns on the two surfaces is confirmed byoptically detecting the patterns on the two surfaces of the sheet (film)7 c, respectively, can also fall within the technical scope of thepresent invention.

In this case, based on the result of the optical detection of the twopatterns, the manipulating portion 131 automatically controls theactuator 129. Thus, the second roll 13 can be moved (forward orbackward) along the shaft direction 13 r. Thus, the positions of thepatterns of the second roll 13 and the third roll 14 (first roll 12)along the shaft directions 13 r and 14 r (12 r), respectively, can beadjusted. The other structures, advantages and effects are similar tothose of the fifth embodiment described above, and therefore theexplanations thereof will be omitted.

[Modification (3) of the Fifth Embodiment]

The fifth embodiment and Modifications (1) and (2) described above arepresumed based on the specification that the hydraulic actuator 129 isapplied to the axial position adjusting mechanism 121, but in place,such a specification that an actuator of some other system is appliedcan also fall within the technical scope of the present invention. Forexample, such an apparatus that moves the adjusting plate 127 forward orbackward by expanding and contracting the piezoelectric element may aswell be apply.

Furthermore, as the actuator of the other system, for example, such anapparatus that moves an adjusting plate jointed with a screw, forward orbackward by rotating the screw by a motor (see JP 2004-142182 A) or suchan apparatus that moves an adjusting plate via a tapered block jointedwith a screw, forward or backward by rotating the screw by a motor (seeJP H10-34748 A, FIG. 7) may be applied.

Additional advantages and modifications will readily occur to thoseskilled in the art. Therefore, the invention in its broader aspects isnot limited to the specific details and representative embodiments shownand described herein. Accordingly, various modifications may be madewithout departing from the spirit or scope of the general inventiveconcept as defined by the appended claims and their equivalents.

What is claimed is:
 1. A double-sided transcription type sheet/filmforming roll apparatus comprising a first roll and a second rollconfigured to be rotatable in opposition to each other, on each of whicha preset pattern is formed and configured to feed a molten resin into apart between the first roll and the second roll to thereby form a sheetor a film on both surfaces of which the patterns are transcribed, theapparatus comprising: a first motor configured to rotate the first roll;a second motor including a rotor on which a plurality of permanentmagnets are arranged, an attaching surface of the rotor, and a rotatingshaft attached to the rotor, the second motor being configured to rotatethe second roll; a disk-like flange part provided at one end of therotating shaft of the second motor and attached by bolt fastening to theattaching surface concentrically; a push-pull unit configured to movethe first roll toward or away from the second roll; a power transmissionmechanism configured to couple the second motor with the second roll,the power transmission mechanism comprising an intermediate bearing partand first and second shaft couplings, the first shaft coupling therotating shaft of the second motor and the intermediate shaft part witheach other, and the second shaft coupling the rotating shaft of thesecond roll and the intermediate shaft part with each other, wherein avariation state of the rotating shaft of the second roll created whenbringing the first roll close to and away from the second roll isabsorbed to be eliminated as the intermediate shaft part is inclinedwith respect to the first shaft coupling as a base point, therebymaintaining a posture of the rotating shaft of the second motor constantat all times; a shaft direction supporting mechanism configured tosupport the second roll along a shaft direction in a state where thesecond roll is rotatable; and an axial position adjusting mechanismconfigured to move the shaft direction supporting mechanism along theshaft direction, the second roll being configured to move in the shaftdirection along the first roll with movement of the shaft directionsupporting mechanism, thereby adjusting the positions of both patternson the first roll and the second roll along the shaft direction.
 2. Theapparatus of claim 1, wherein the axial position adjusting mechanismfurther comprises, in addition to the shaft direction supportingmechanism, an adjusting plate configured to move the second motor andthe power transmission device integrally along the shaft direction. 3.The apparatus of claim 2, wherein the axial position adjusting mechanismcomprises a hydraulic actuator configured to move the adjusting plateforward and backward with an oil pressure.
 4. The apparatus of claim 3,wherein the axial position adjusting mechanism comprises a preloadmechanism configured to apply a given pressure to the hydraulicactuator.
 5. The apparatus of claim 1, wherein the intermediate shaftpart is an integrated single axial member or prepared from a pluralityof axial members coupled with each other.
 6. The apparatus of claim 1,wherein the shaft couplings are each a flexible coupling or a balljoint.
 7. A double-sided transcription type sheet/film forming rollapparatus comprising a first roll and a second roll configured to berotatable in opposition to each other, a third roll rotatable insynchronism with the second roll, on each of the second roll and thethird roll, a preset pattern is formed and configured to feed a moltenresin into a part between the first roll and the second roll to form asheet or a film on both surfaces of which the patterns are transcribed,as the molten resin passes through between the second roll and the thirdroll, the apparatus comprising: a first motor configured to rotate thefirst roll; a second motor including a rotor on which a plurality ofpermanent magnets are arranged, an attaching surface of the rotor, and arotating shaft attached to the rotor, the second motor being configuredto rotate the second roll; a disk-like flange part provided at one endof the rotating shaft of the second motor and attached by bolt fasteningto the attaching surface concentrically; a push-pull unit configured tomove the first roll toward or away from the second roll; a powertransmission mechanism configured to couple the second motor with thesecond roll, the power transmission mechanism comprising an intermediatebearing part and first and second shaft couplings, the first shaftcoupling the rotating shaft of the second motor and the intermediateshaft part with each other, and the second shaft coupling the rotatingshaft of the second roll and the intermediate shaft part with eachother, wherein a variation state of the rotating shaft of the secondroll created when bringing the first roll close to and away from thesecond roll is absorbed to be eliminated as the intermediate shaft partis inclined with respect to the first shaft coupling as a base point,thereby maintaining a posture of the rotating shaft of the second motorconstant at all times; a shaft direction supporting mechanism configuredto support the second roll along a shaft direction in a state where thesecond roll is rotatable; and an axial position adjusting mechanismconfigured to move the shaft direction supporting mechanism along theshaft direction, the second roll being configured to move in the shaftdirection along the third roll with movement of the shaft directionsupporting mechanism, thereby adjusting the positions of both patternson the second roll and the third roll along the shaft direction.
 8. Theapparatus of claim 7, wherein the axial position adjusting mechanismfurther comprises, in addition to the shaft direction supportingmechanism, an adjusting plate configured to move the second motor andthe power transmission device integrally along the shaft direction. 9.The apparatus of claim 7, wherein the intermediate shaft part is anintegrated single axial member or prepared from a plurality of axialmembers coupled with each other.
 10. The apparatus of claim 7, whereinthe shaft couplings are each a flexible coupling or a ball joint.